High-speed multinozzle additive manufacturing and extrusion modeling of large-scale microscaffold networks

Chauvette, Jean‐François; Brzeski, David; Hia, Iee Lee; Farahani, Rouhollah D.; Piccirelli, Nicola; Therriault, Daniel

doi:10.1016/j.addma.2021.102294

Cited by 6 publications

(4 citation statements)

References 23 publications

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“…If the printhead movement speed is too small, less than the speed of the extrusion of composite materials from the bin, the material deposited on the print substrate per unit time is larger, and thus the actual line width will be larger than the theoretical line width. If the printhead movement speed is greater than the extrusion speed of the composite materials, the flow of the composite materials deposited per unit time is smaller, so that the thickness of each layer of the structure is much smaller than the theoretical thickness, and the overall size of the artificial bone will also deviate from the design size after the layers are stacked [ 37 ].…”

Section: Resultsmentioning

confidence: 99%

3D Printing and Performance Study of Porous Artificial Bone Based on HA-ZrO2-PVA Composites

Bie¹,

Chen

Shan

et al. 2023

Materials

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An ideal artificial bone implant should have similar mechanical properties and biocompatibility to natural bone, as well as an internal structure that facilitates stomatal penetration. In this work, 3D printing was used to fabricate and investigate artificial bone composites based on HA-ZrO2-PVA. The composites were proportionally configured using zirconia (ZrO2), hydroxyapatite (HA) and polyvinyl alcohol (PVA), where the ZrO2 played a toughening role and PVA solution served as a binder. In order to obtain the optimal 3D printing process parameters for the composites, a theoretical model of the extrusion process of the composites was first established, followed by the optimization of various parameters including the spray head internal diameter, extrusion pressure, extrusion speed, and extrusion line width. The results showed that, at the optimum parameters of a spray head diameter of 0.2 mm, extrusion pressure values ranging from 1–3 bar, a line spacing of 0.8–1.5 mm, and a spray head displacement range of 8–10 mm/s, a better structure of biological bone scaffolds could be obtained. The mechanical tests performed on the scaffolds showed that the elastic modulus of the artificial bone scaffolds reached about 174 MPa, which fulfilled the biomechanical requirements of human bone. According to scanning electron microscope observation of the scaffold sample, the porosity of the scaffold sample was close to 65%, which can well promote the growth of chondrocytes and angiogenesis. In addition, c5.18 chondrocytes were used to verify the biocompatibility of the composite materials, and the cell proliferation was increased by 100% when compared with that of the control group. The results showed that the composite has good biocompatibility.

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Section: Resultsmentioning

confidence: 99%

3D Printing and Performance Study of Porous Artificial Bone Based on HA-ZrO2-PVA Composites

Bie¹,

Chen

Shan

et al. 2023

Materials

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“…[ 38 ] The material's process‐related apparent viscosity η app at high shear rate was measured using capillary rheology method at room temperature for process‐related apparent shear rate

{\dot{\gamma }}_w

> 10 3 s −1 . [ 48,62 ] Results for η and η app were fitted using a power law model η = K

\dot{\gamma }

n −1 .…”

Section: Methodsmentioning

confidence: 99%

“…[ 45–47 ] The addition of a multinozzle printhead to a 6‐axis robot arm has been shown to reduce the time it takes to print high‐resolution large‐scale microscaffold networks made of thermosetting polymer. [ 48,49 ]…”

Section: Introductionmentioning

confidence: 99%

“…[45][46][47] The addition of a multinozzle printhead to a 6-axis robot arm has been shown to reduce the time it takes to print high-resolution large-scale microscaffold networks made of thermosetting polymer. [48,49] In this work, two different AM technologies, including FFF of HTRP and multinozzle DIW of a thermosetting composite are integrated into a multiprocess AM approach using a 6axis robot arm to demonstrate a manufacturing proof-of-concept of a large-scale non-planar complex multifunctional part. The achievement of this objective is demonstrated by manufacturing a relatively large non-planar aircraft component demonstrator, composed of a curved high-performance thermoplastic sandwich panel and a network of interconnected abradable thermosetting microscaffolds.…”

Section: Introductionmentioning

confidence: 99%

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Non‐Planar Multiprocess Additive Manufacturing of Multifunctional Composites

Chauvette

Hia

Pierre

et al. 2023

Adv Materials Technologies

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Multiprocess additive manufacturing (AM) consists of integrating different 3D printing techniques to enable the fabrication of multifunctional parts, based on their geometry and material properties. The combination of fused filament fabrication (FFF) and direct ink writing (DIW) techniques, respectively involving thermoplastics and thermosetting polymers (or composites), often focuses on planar and small‐scale applications (i.e., few cm), with limited nozzle orientation freedom for the fabrication of complex parts. Many industries, such as the aerospace sector, could benefit from the AM of lightweight multifunctional parts. For instance, one of the key aircraft components, the abradable seal coating, is applied on gas turbine engines casing to increase engine efficiency and is mechanically abraded by the rotor blades during engine startup. Abradable coatings made of thermosetting polymer could be 3D‐printed using a multiprocess to obtain more functionalities. In this work, a non‐planar multiprocess AM approach involving FFF of a complex large sandwich panel structure with low material density and large‐scale DIW of an abradable thermosetting coating with controlled porosity for sound absorption potential, and better mechanical abradability than a commercial product, is presented. This multiprocess AM approach can be used to manufacture lightweight multifunctional structural parts for the automotive or aerospace industries.

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Bio‐Inspired Fog Harvesting Meshes: A Review

Kennedy,

Boreyko

2023

Adv Funct Materials

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Freshwater scarcity has become a critical global challenge affecting some of the most vulnerable populations. In response, significant effort has focused on ways to increase access to this precious resource. Within the context of geographical, cultural, political, and technological factors governing freshwater availability, atmospheric water harvesting (AWH) has demonstrated tremendous promise to help address these shortages. Specifically, mesh‐based fog harvesters have received considerable attention for their passive qualities compared with their energy‐dependent technological siblings (sorbents, condensation, etc.), yet their specific water yield (SY) has developed only modestly in recent decades. While the plant and animal kingdom provide diverse examples of passive fog collection, and science has developed a remarkable understanding of these processes, much of this knowledge has yet to be translated practically at scale. This is partially due to challenges in mass‐producing complex (often micro‐scale) structures observed in nature. Fortunately, manufacturing technology is catching up with scientific understanding, especially at the scale of mesh design. To this end, the review begins by surveying bioinspired research in fog harvesting. Afterward, this study identifies milestones in developing bioinspired fog harvesting meshes, concluding in a discussion of future mesh research opportunities connecting bioinspiration and emerging advanced manufacturing techniques.

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High-speed multinozzle additive manufacturing and extrusion modeling of large-scale microscaffold networks

Cited by 6 publications

References 23 publications

3D Printing and Performance Study of Porous Artificial Bone Based on HA-ZrO2-PVA Composites

3D Printing and Performance Study of Porous Artificial Bone Based on HA-ZrO2-PVA Composites

Non‐Planar Multiprocess Additive Manufacturing of Multifunctional Composites

Bio‐Inspired Fog Harvesting Meshes: A Review

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