Hybrid material additive manufacturing: interlocking interfaces for fused filament fabrication on laser powder bed fusion substrates

Englert, Lukas; Heuer, Anselm; Engelskirchen, Mathias Keanu; Frölich, Felix; Dietrich, Stefan; Liebig, Wilfried V.; Kärger, Luise; Schulze, Volker

doi:10.1080/17452759.2022.2048228

Cited by 15 publications

(17 citation statements)

References 19 publications

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“…S/A availability appeared to have a direct effect on the separation force and failure mechanism of the specimens, whereby those with fewer sidewalls (SW) to which to adhere recorded the lowest separation forces and generally displayed Type 1 failure across all infill levels e.g., triangular (3 SW) = 100%, octahedral (4 SW) = 89%, grid (4 SW) = 89%, honeycomb (6 SW) = 22% and gyroid (continuous SW + porous network) = 0% Type 1 failure. Similarly, Englert et al [ 47 ] showed that higher S/A in their interlocking specimens aided polylactic acid (PLA) ingress and attachment to aluminum specimens, in turn reducing pull-out style failure in tension.…”

Section: Discussionmentioning

confidence: 99%

Investigating the Feasibility and Performance of Hybrid Overmolded UHMWPE 3D-Printed PEEK Structural Composites for Orthopedic Implant Applications: A Pilot Study

Smith,

Basgul,

Mohammadlou

et al. 2024

Bioengineering

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Ultra-high-molecular-weight polyethylene (UHMWPE) components for orthopedic implants have historically been integrated into metal backings by direct-compression molding (DCM). However, metal backings are costly, stiffer than cortical bone, and may be associated with medical imaging distortion and metal release. Hybrid-manufactured DCM UHMWPE overmolded additively manufactured polyetheretherketone (PEEK) structural components could offer an alternative solution, but are yet to be explored. In this study, five different porous topologies (grid, triangular, honeycomb, octahedral, and gyroid) and three surface feature sizes (low, medium, and high) were implemented into the top surface of digital cylindrical specimens prior to being 3D printed in PEEK and then overmolded with UHMWPE. Separation forces were recorded as 1.97–3.86 kN, therefore matching and bettering the historical industry values (2–3 kN) recorded for DCM UHMWPE metal components. Infill topology affected failure mechanism (Type 1 or 2) and obtained separation forces, with shapes having greater sidewall numbers (honeycomb-60%) and interconnectivity (gyroid-30%) through their builds, tolerating higher transmitted forces. Surface feature size also had an impact on applied load, whereby those with low infill-%s generally recorded lower levels of performance vs. medium and high infill strategies. These preliminary findings suggest that hybrid-manufactured structural composites could replace metal backings and produce orthopedic implants with high-performing polymer–polymer interfaces.

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Section: Discussionmentioning

confidence: 99%

Investigating the Feasibility and Performance of Hybrid Overmolded UHMWPE 3D-Printed PEEK Structural Composites for Orthopedic Implant Applications: A Pilot Study

Smith,

Basgul,

Mohammadlou

et al. 2024

Bioengineering

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“…Hybrid 3D printing, known as multi-step 3D printing or multi-process 3D printing, is a fresh field of research in which basic 3D printing is enhanced with complementary processes to create objects with multi-material and multifunctionality [139][140][141]. In comparison to a single 3D printing technique, hybrid 3D printing has demonstrated numerous outstanding advantages in developing novel tissue scaffolds: (i) programmable integration of multiple biomaterials, including spatial control of material (cell), geometry, scale, and dimension [142]; (ii) designable couplings of multiple biofunctions such as antibacterial, osteogenic, angiogenic, and anti-tumor [143]; (iii) process flexibility enhancement to eliminating the limitations of a single 3D printing technique while integrating the advantages of traditional manufacturing, such as a subtractive process machine interlocking root structures [144]. (iv) Expanded clinical applications for bone tissue repair, such as holistic osteochondral repair in joints with vastly different mechanical and biological requirements [145].…”

Section: Hybrid 3d Printingmentioning

confidence: 99%

3D/4D printed bio-piezoelectric smart scaffolds for next-generation bone tissue engineering

Chen

et al. 2023

Int. J. Extrem. Manuf.

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Piezoelectricity in native bones has been well recognized as the key factor in bone regeneration. Thus, bio-piezoelectric materials have gained substantial attention in repairing damaged bone by mimicking the tissue's electrical microenvironment (EM). However, traditional manufacturing strategies still encounter limitations in creating personalized bio-piezoelectric scaffolds, hindering their clinical applications. Three-dimensional (3D)/four-dimensional (4D) printing technology based on the principle of layer-by-layer forming and stacking of discrete materials has demonstrated outstanding advantages in fabricating bio-piezoelectric scaffolds in a more complex-shaped structure. Notably, 4D printing functionality-shifting bio-piezoelectric scaffolds can provide a time-dependent programmable tissue EM in response to external stimuli for bone regeneration. In this review, we first summarize the physicochemical properties of commonly used bio-piezoelectric materials (including polymers, ceramics, and their composites) and representative biological findings for bone regeneration. Then, we discuss the latest research advances in the 3D printing of bio-piezoelectric scaffolds in terms of feedstock selection, printing process, induction strategies, and potential applications. Besides, some related challenges such as feedstock scalability, printing resolution, stress-to-polarization conversion efficiency, and non-invasive induction ability after implantation have been put forward. Finally, we highlight the potential of shape/property/functionality-shifting smart 4D bio-piezoelectric scaffolds in bone tissue engineering. Taken together, this review emphasizes the appealing utility of 3D/4D printed biological piezoelectric scaffolds as next-generation bone tissue engineering implants.

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“…Therefore, there has been a growing interests to fabricate a dissimilar multi-material part using hybrid manufacturing, also known as multi-step 3D printing or multi-process 3D printing [45].In hybrid manufacturing, a subtractive process can also be used to machine interlocking root structures on a metal part where the additive process continues to print polymer features beyond the interlock which secures the joining of metal and polymer [46]. Alternatively, a metallic structure with intricate interlock features can be fabricated by powder bed fusion and subsequently printed with polymer features via material extrusion [47]. Besides metal and polymer, two different polymer types such as photopolymer resin and thermoplastic powder can also be combined via hybrid manufacturing to obtain PBF strength and VP surface finish [48].…”

Section: Hybrid Additive Manufacturingmentioning

confidence: 99%

Multi-material and Multi-dimensional 3D Printing for Biomedical Materials and Devices

Leong

2022

Biomedical Materials & Devices

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In recent years, Additive Manufacturing (AM) has evolved into a "multi-x" era, such as multi-part design, multi-material, multi-process, multi-mode, multi-scale, multi-dimension, and multi-function. These emerging new features of AM present both tremendous opportunities and challenges for developing and regulating new and novel biomedical materials and devices. This paper focuses on two aspects, namely multi-material and multi-dimension AM. In multi-material 3D printing, the layering step is the key. Modifying the layering method yet without changing the solidifying or bonding principles governing the AM process can enable and significantly advance multi-material 3D printing. In multi-dimensional 3D printing, typically 4D printing and 5D printing, the meaning of "D" is suggested to refer to space-time dimension rather than the number of degrees of freedom in physical space. It is proposed in this paper that an alternative dimension (or 5D) for future 3D printing processes can be that of scale. Scale here refers the different levels of resolution that are used simultaneously within a print. In such a scale dimension, continuous printing of cross-scale or varied resolution design features in a single build process without affecting the overall printing speed and time would be highly desirable. This is probably the first paper reflecting on multi-material 3D printing from the perspective of layering and on multi-dimensional 3D printing with regard to its future development.

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Hybrid material additive manufacturing: interlocking interfaces for fused filament fabrication on laser powder bed fusion substrates

Cited by 15 publications

References 19 publications

Investigating the Feasibility and Performance of Hybrid Overmolded UHMWPE 3D-Printed PEEK Structural Composites for Orthopedic Implant Applications: A Pilot Study

Investigating the Feasibility and Performance of Hybrid Overmolded UHMWPE 3D-Printed PEEK Structural Composites for Orthopedic Implant Applications: A Pilot Study

3D/4D printed bio-piezoelectric smart scaffolds for next-generation bone tissue engineering

Multi-material and Multi-dimensional 3D Printing for Biomedical Materials and Devices

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