Search Results (1,171)

As 3D printing technology expands rapidly in medical disciplines, the accuracy evaluation of 3D-printed medical models is required. However, no established guidelines to assess the dimensional error of anatomical models exist. This study aims to evaluate the dimensional accuracy of medical models 3D-printed using a hospital-based Fused Deposition Modeling (FDM) 3D printer. Two dissected cadaveric right hands were marked with Titanium Kirshner wires to identify landmarks on the heads and bases of all metacarpals and proximal and middle phalanges. Both hands were scanned using a Cone Beam Computed Tomography scanner. Image post-processing and segmentation were performed on 3D Slicer software. Hand models were 3D-printed using a professional hospital-based FDM 3D printer. Manual measurements of all landmarks marked on both pairs of cadaveric and 3D-printed hands were taken by two independent observers using a digital caliper. The Mean Absolute Difference (MAD) and Mean Dimensional Error (MDE) were calculated. Our results showed an acceptable level of dimensional accuracy. The overall study’s MAD was 0.32 mm (±0.34), and its MDE was 1.03% (±0.83). These values fall within the recommended range of errors. A high level of dimensional accuracy of the 3D-printed anatomical models was achieved, suggesting their reliability and suitability for medical applications. Full article

In the V-bending of sheet metals using a pair of plastic punch and die manufactured by a 3D printer, the effects of two different dimensions designed with the same tool geometry on the deformation behaviors of the punch, die, and sheet were evaluated. The deformation behavior and strain distribution of the punch, die, and sheet were analyzed using a digital image correlation method. Sheets from pure aluminum to ultra-high-strength steel were bent using the two tools with different spans; one was designed on the assumption of tool steel material, and the other was designed on the assumption of plastic material. In both tools, the large compressive strain appeared around the center of the punch tip and on the corners of the die. The tools with a long span for the plastic material gave a lower bending force and small deformation of the plastic tools. The angle difference between a bent sheet at the bottom dead center and a tool was smaller for the tools with the long span, although the springback in the bent sheet appeared. It was found that the design method on the assumption of the plastic material is effective for the V-bending plastic tools. Full article

The purpose of this systematic review was to evaluate three mechanical properties of 3D-printed resins for indirect restorations according to published scientific evidence. This systematic review was conducted according to the PRISMA statement (preferred reporting elements for systematic reviews and meta-analyses). The search was performed by two investigators, (DD) and (VB), and a third (AC) resolved disagreements. Articles were searched in four digital databases: PubMed, EBSCO, Lilacs, and Science Direct, starting on 18 February 2024. As 3D-printing technology has shown significant advances in the last 5 years, the review was conducted with a publication year range between 2019 and 2024, in English language and included in vitro articles on the mechanical properties of flexural strength, fatigue behavior, and microhardness of 3D-printed materials for temporary or definitive restorations. MeSH terms and free terms were used for the titles and abstracts of each article. Finally, the QUIN tool was used to assess the risk of bias. In the main search, 227 articles were found, of which 20 duplicates were excluded, leaving 207 articles; of these, titles and abstracts were read, and 181 that did not meet the eligibility criteria were eliminated; of the remaining 26 articles, 1 article was eliminated for not presenting quantitative results. Regarding publication bias, 6 of the 25 articles had a low risk of bias, 18 had a medium risk of bias, and 1 had a high risk of bias. It may be concluded that 3D-printed resins have lower flexural strength, fatigue behavior, and microhardness than other resin types used for the fabrication of temporary and permanent restorations. The type of 3D printer and polymerization time could be factors that significantly affect the flexural strength, fatigue behavior and microhardness of 3D-printed resins. Based on existing evidence, it should be considered that additive technology has promising future prospects for temporary and permanent dental restorations. Full article

The aim of this study was to develop three-dimensional anatomical models of dogs with congenital extrahepatic portosystemic shunts (CEPSs) using 3D printing, as well as to detail their development process and compare the final models to volume rendering (VR) derived from computed tomography (CT) scans. CT scans in the Digital Imaging and Communications in Medicine (DICOM) format of two canine patients were used—one with splenocaval deviation and the other with right gastrocaval deviation. The images were segmented using 3DSlicer software, generating 3D files in Standard Tessellation Language (STL) format, which were then subjected to refinement and mesh adjustment using Blender software. The models were printed on a J750™ Digital Anatomy™ printer, followed by post-processing in a 2% sodium hydroxide solution for 72 h, with subsequent rinsing to remove support resin residues. The printed models showed colored anatomical structures, including the liver; spleen; kidneys; part of the arterial, venous, and portal circulations; and CEPSs. For comparison purposes, VR of the scans was recreated in the RadiAnt DICOM Viewer software. Despite some limitations of the segmentation software, the 3D-printed models effectively represented the anatomy of the patients and the CEPSs, demonstrating good equivalence to the VR. Full article

This work presents a multilamination method for fabricating microfluidic devices or analytical microsystems using commercial 3D printers and photocurable resins as primary components. The developed method was validated by fabricating devices for the colorimetric measurement of copper ions in aqueous solutions, achieving results comparable to traditional cyclic olefin copolymer (COC) systems. The microfluidic platforms demonstrated stability and functionality over a twelve-week testing period. Channels with minimum dimensions of 0.4 mm × 0.4 mm were fabricated, and the feasibility of using resin modules for optical applications was demonstrated. This study highlights the potential of combining 3D printing with multilamination procedures as a versatile alternative, offering flexibility through the selection of a variety of available resins and commercial printers, as well as the ease of design development. This method offers significant reductions in cost, time, and manufacturing complexity by eliminating the need for equipment such as CNC machines, presses, and ovens, which are typically required in other multilamination technologies like LTCC and COC. Full article

Three-dimensional printing is a transformative technology in the manufacturing industry which provides customization and cost-effectiveness for all walks of life due to its fast molding speed, high material utilization, and direct molding of arbitrary complex structural parts. This study aims to improve the molding accuracy of 3D printed polyether ether ketone (PEEK) samples by systematically studying key process parameters, including printing speed, layer thickness, nozzle temperature, and filling rate. The 3D printing nozzle has an important impact on the extrusion rate of the melt, and the fluid simulation of the nozzle was carried out to explore the variation characteristics of the melt flow rate in the nozzle and optimize the nozzle structure parameters. In order to effectively optimize the process, considering its inherent efficiency, robustness, and cost-effectiveness, the L9 orthogonal array experimental design scheme was used to analyze the effects of printing speed, layer thickness, nozzle temperature, and filling rate on the molding accuracy of the test sample, and the optimal combination of process parameters was optimized through the comprehensive weighted scoring method so as to improve the molding accuracy of the 3D printed PEEK sample; finally, the molding accuracy of the components printed using the Sermoon-M1 3D printer with the optimized nozzle structure was printed. The results show that the nozzle structure is optimal when the convergence angle is 120° and the aspect ratio is 2, and the outlet cross-section velocity is increased by 2.5% and 2.7%, respectively. The order of influence strength on the dimensional accuracy of the test sample is layer thickness > filling rate > nozzle temperature > printing speed. The optimal combination of parameters is: a printing speed of 15 mm/s, a layer thickness of 0.1 mm, a nozzle temperature of 420 °C, and a filling rate of 50%. The insights derived from this study pave the way for predicting and implementing the selection of optimal process parameters in the production of 3D printed products, with important implications for the optimal molding accuracy of printed components. Full article

This study presents the development of a novel biodegradable, self-expanding stent designed to facilitate arteriovenous fistula (AVF) maturation. The stent, made of polylactic acid (PLA), is engineered to be crimped into a standard 6 Fr (2 mm) catheter for delivery and to self-expand, increasing the vein diameter beyond 4.2 mm with the aid of pre-strained elastic lines, thereby enhancing maturation rates. A validated finite element model was utilized to design the stent, ensuring it meets functional requirements with less than 3% strain in both crimped and fully expanded states. The stent prototype was fabricated using a modified fused deposition modeling (FDM) 3D printer, and the Taguchi method was employed to optimize manufacturing parameters, achieving strut width and thickness variations of less than 5%. Experimental validation demonstrated that the PLA stent could be crimped to 2 mm, self-expand to 6.4 mm, and deliver a radial force of 0.08 N/mm, meeting the performance requirements of AVF stents. Additionally, the stent exhibits excellent elasticity post-implantation, minimizing the risk of damage from external forces, and fully degrades after AVF maturation, reducing the risk of long-term vascular obstruction and related complications. This novel stent design offers a promising biodegradable solution for enhancing AVF maturation and improving patient outcomes. Full article

This study investigates the impact of printing layer orientation on the mechanical properties of 3D-printed temporary prosthetic materials. Traditionally, temporary prostheses are fabricated using acrylic resin (polymethyl methacrylate), but advancements have introduced bis-acrylic resins, CAD/CAM-based acrylic resin (milled), and 3D printing technologies. In 3D printing, material is manufactured in overlapping layers, which can be oriented in different directions, directly affecting the material’s resistance. Specimens were designed as bars (2 mm × 2 mm × 25 mm) and grouped according to their printing orientation: BP0 (0 degrees), BP45 (45 degrees), and BP90 (90 degrees). The models were created using Fusion 360 software (version 2.0.12600) and printed on a 3D DLP printer with DLP Slicer software (Chitu DLP Slicer, CBD Tech, version v1.9.0). The bars were then subjected to 3-point bending tests using an Instron Universal Testing Machine to measure Flexural Strength (FS) and Flexural Modulus (FM). Results demonstrated that the BP90 group exhibited the highest Flexural Strength (114.71 ± 7.61 MPa), followed by BP45 (90.10 ± 8.45 MPa) and BP0 (80.90 ± 4.01 MPa). Flexural Modulus was also highest in the BP90 group (3.74 ± 3.64 GPa), followed by BP45 (2.85 ± 2.70 GPa) and BP0 (2.52 ± 2.44 GPa). Significant statistical differences (p < 0.05) were observed, indicating changes in the mechanical properties of the 3D-printed material. The study concludes that printing orientation significantly influences the mechanical properties of temporary prosthetic materials, making the selection of an optimal orientation essential to enhance material performance for its intended application. Full article

Background: Implant surgical guides manufactured in-house using 3D printing technology are widely used in clinical practice to translate virtual planning to the operative field. Aim: The present in vitro study investigated the dimensional changes of 3D surgical guides printed in-house using Shining 3D surgical guide resin (SG01). Materials and methods: Five test bodies, varying in shape and dimensions, were designed using computer-aided design (CAD) software and manufactured using three different Light Crystal Display (LCD) 3D printers (AccuFab-L4D, Elegoo Mars Pro 3, and Zortrax Inspire). Specific printing and post-processing parameters for the SG01 resin were set to produce 25 test bodies (5 of each shape) from each of the three printers, resulting in a total of 75 samples. The dimensional changes were evaluated using a digital calliper at four different time points: immediately after printing (T0), one month after storage (T1), immediately after sterilization (T2), and one month after sterilization (T3). Results: All the test bodies showed deviations from the overall CAD reference value of 12.25 mm after printing and post-processing (T0) and following steam sterilization (T2). Similar trends were observed for the effect of storage times at T1 and T3. The AccuFab prints demonstrated a better dimensional stability than the Elegoo and Zortrax samples. Conclusions: The LCD 3D printers, sterilization, and storage times influenced the dimensional stability of the test bodies made with SGO1 resin. Full article

The advancement of medical 3D printing technology includes several enhancements, such as decreasing the length of surgical procedures and minimizing anesthesia exposure, improving preoperative planning, creating personalized replicas of tissues and bones specific to individual patients, bioprinting, and providing alternatives to human organ transplants. The range of materials accessible for 3D printing within the healthcare industry is significantly narrower when compared with conventional manufacturing techniques. Liquid silicone rubber (LSR) is characterized by its remarkable stability, outstanding biocompatibility, and significant flexibility, thus presenting substantial opportunities for manufacturers of medical devices who are engaged in 3D printing. The main objective of this study is to develop, refine, and assess a 3D printer that can employ UV-cured silicone for the fabrication of aortic heart valves. Additionally, the research aims to produce a 3D-printed silicone aortic heart valve and evaluate the feasibility of the final product. A two-level ANOVA experimental design was utilized to investigate the impacts of print speed, nozzle temperature, and layer height on the print quality of the aortic heart valve. The findings demonstrated that the 3D-printed heart valve’s UV-cured silicone functioned efficiently, achieving the target flow rates of 5 L/min and 7 L/min. Two distinct leaflet thicknesses (LT) of the heart valve, namely 0.8 mm and 1.6 mm, were also analyzed to simulate calcium deposition on the leaflets. Full article

With the advancement of Industry 4.0, 3D printing has become a critical technology in smart manufacturing; however, challenges remain in the integrated management, quality control, and remote monitoring of multiple 3D printers. This study proposes an intelligent cloud monitoring system based on the SharkNet dynamic network, IoT, and artificial neural networks (ANNs). The system utilizes a SharkNet dynamic network to integrate low-cost sensors for environmental monitoring to enable low-latency data transmission and deploys ANN models on the cloud for print quality prediction and process parameter optimization. Next, we experimentally validated the system using the Taguchi design and ANN-based analysis, focusing on optimizing printing process parameters and improving surface quality. The main results show that the designed system has a communication delay of 40–50 ms and 99.8% transmission reliability under moderate load, and the system reduces the surface roughness prediction error to less than 17.2%. In addition, the ANN model outperforms conventional methods in capturing the nonlinear relationships of the variables, and the system can be based on the model to improve print quality and productivity by enabling real-time parameter adjustments. The system retains a high degree of scalability in terms of real-time monitoring and parallel or complex control of multiple devices, which demonstrates its potential for applications in smart manufacturing. Full article

This study evaluated the internal and marginal accuracy (trueness and precision) of zirconia laminate veneers fabricated using the DLP printing and milling method, employing 3D analysis software program. The maxillary central incisor tooth of a typodont model was prepared by a dentist and scanned using a desktop scanner. An anatomical zirconia laminate was designed using computer-aided design (CAD) software and saved in a standard tessellation language (STL) format. Thirty zirconia laminates were manufactured using a milling machine (MLL group) and a DLP printer (PTL group). All the specimens were scanned, and their internal and marginal areas were edited accordingly. The root-mean-square value was used to assess the accuracy of the internal and marginal areas of the zirconia laminates. Statistical significance was evaluated using the Mann–Whitney U test. Statistically significant differences were found in RMS values for both groups in the internal and marginal areas (p < 0.001 and p = 0.034, respectively). The MLL and PTL groups differed significantly in terms of precision (p = 0.017), but not at the margin (p = 0.361). DLP-printed zirconia laminates demonstrated stable and consistent performance, making the technique a reliable option for producing esthetic prostheses. Full article

The porous structure, in which many pores are intentionally placed inside the material, has excellent impact energy absorption properties. Recent studies have attempted to fabricate multi-layered porous structures with different mechanical properties within a single porous structure sample, and the mechanical properties of these structures are being elucidated. However, these studies mainly attempted to vary the densities, pore structures, and alloy compositions within a single material, such as aluminum, for the entire sample. Since multi-materials are now being promoted to utilize the most suitable material type in the right place, porous structures made of different materials, such as a combination of aluminum and resin, are expected to be required in the future. In this study, we attempted to fabricate two-layered porous structure samples of different materials by printing a resin porous structure using a 3D printer on an aluminum foam fabricated by a precursor foaming process. Static compression tests were performed on the resulting two-layered porous structure samples to investigate their mechanical properties. The resin porous structure printed by the 3D printer and the aluminum foam were both designed to expose the porous structure on the surface of the specimen so that the deformation behavior can be easily observed. The density of the resin porous structure was varied by systematically varying the filling rate of the resin porous structure to be printed, and the effect on the compression properties was investigated. The fabricated two-layered porous structure was effectively bonded between the two layers by the anchor effect, which is a mechanical bonding caused by the resin penetrating into the pores. The layers exhibited robust bonding with no evidence of separation. It was possible to fabricate a two-layered porous structure that exhibited both properties of aluminum foam and those of resin porous structure. It was found that the plateau stress in the resin porous structure layer can be controlled between about 0.5 MPa and 40 MPa, and the deformation behavior and energy absorption properties of the two-layered porous structure can be controlled by varying the resin filling rate of the resin porous structure layer. That is, it was indicated that multi-layered porous structures with various densities and consisting of various types of materials allow for the optimal design of porous structures used in structural materials. Full article

Terrestrial laser scanners (TLS) are portable dimensional measurement instruments used to obtain 3D point clouds of objects in a scene. While TLSs do not require the use of cooperative targets, they are sometimes placed in a scene to fuse or compare data from different instruments or data from the same instrument but from different positions. A contrast target is an example of such a target; it consists of alternating black/white squares that can be printed using a laser printer. Because contrast targets are planar as opposed to three-dimensional (like a sphere), the center of the target might suffer from errors that depend on the orientation of the target with respect to the TLS. In this paper, we discuss a low-cost method to characterize such errors and present results obtained from a short-range TLS and a long-range TLS. Our method involves comparing the center of a contrast target against the center of spheres and, therefore, does not require the use of a reference instrument or calibrated objects. For the short-range TLS, systematic errors of up to 0.5 mm were observed in the target center as a function of the angle for the two distances (5 m and 10 m) and resolutions (30 points-per-degree (ppd) and 90 ppd) considered for this TLS. For the long-range TLS, systematic errors of about 0.3 mm to 0.8 mm were observed in the target center as a function of the angle for the two distances (5 m and 10 m) at low resolution (28 ppd). Errors of under 0.3 mm were observed in the target center as a function of the angle for the two distances at high resolution (109 ppd). Full article

The growing production of plastic waste and its recycling, from a circular economy perspective, faces challenges in finding solutions that are easy to implement, cheap in labor and energy during recycling, and locally implementable to avoid transportation. This work developed and validated a methodology to address these challenges. Designed for small-scale use at home or in schools following a Do It Yourself (DIY) approach, it transforms water bottles into plastic strips, which, after passing through an extruder nozzle, become filaments with a diameter of 1.75 mm. These can replace commercially available thermoplastic filaments. Specimens produced by additive manufacturing with recycled PET (rPET) and commercial PETG showed similar mechanical properties and can serve as alternatives to commercial PETG. PETG shows higher strength (30 MPa) compared to rPET (24 MPa), a slightly higher Young’s modulus of 1.44 GPa versus 1.43 GPa, and greater strain at failure with 0.03 mm/mm against 0.02 mm/mm, making it stiffer and more ductile. This simple and widely applicable local solution may absorb a considerable amount of bottle waste, offering an economical, sustainable alternative to commercial filaments. Full article