scholarly journals Optically Clear and Resilient Free-Form µ-Optics 3D-Printed via Ultrafast Laser Lithography

Materials ◽  
2017 ◽  
Vol 10 (1) ◽  
pp. 12 ◽  
Author(s):  
Linas Jonušauskas ◽  
Darius Gailevičius ◽  
Lina Mikoliūnaitė ◽  
Danas Sakalauskas ◽  
Simas Šakirzanovas ◽  
...  
Keyword(s):  
Ultrafast Laser ◽  
Free Form ◽  
Laser Lithography ◽  
3D Printed

scholarly journals Optically Clear and Resilient Free-Form µ-Optics 3D-Printed via Ultrafast Laser Lithography

2016 ◽  
Author(s):  
Linas Jonušauskas ◽  
Darius Gailevičius ◽  
Lina Mikoliūnaitė ◽  
Danas Sakalauskas ◽  
Simas Šakirzanovas ◽  
...  
Keyword(s):  
Optical Fibers ◽  
High Irradiance ◽  
Pulse Generation ◽  
Ultrafast Laser ◽  
Free Form ◽  
Laser Lithography ◽  
Photonic Lattices ◽  
3D Printed ◽  
Pulsed Exposure

We introduce optically clear and resilient free-form micro-optical of pure (non-photosensitized) organic-inorganic SZ2080 material made by femtosecond 3D laser lithography (3DLL). This is advantageous for rapid printing of 3D micro-/nanooptics, including their integration directly onto optical fibers. A systematic study on the fabrication peculiarities and quality of resultant structures is performed. Comparison of microlenses’ resiliency to CW and femtosecond pulsed exposure is determined. Experimental results prove that pure SZ2080 is ∼3 fold more resistant to high irradiance as compared with a standard photo-sensitized material and can sustain up to 1.91 GW/cm2 intensity. 3DLL is a promising manufacturing approach for high-intensity micro-optics for emerging fields in astro-photonics and atto-second pulse generation. Additionally, pyrolysis is employed to shrink structures up to 40% by removing organic SZ2080 constituents. This opens a promising route towards downscaling photonic lattices and creation of mechanically robust glass-ceramic structures.

scholarly journals Multi-Material 3D Printing of a Customized Sports Mouth Guard: Proof-of-Concept Clinical Case

2021 ◽  
Vol 18 (23) ◽  
pp. 12762
Author(s):  
Alexey Unkovskiy ◽  
Fabian Huettig ◽  
Pablo Kraemer-Fernandez ◽  
Sebastian Spintzyk
Keyword(s):  
3D Printing ◽  
Free Form ◽  
Proof Of Concept ◽  
Virtual Design ◽  
Digital Workflow ◽  
Protective Function ◽  
Drop On Demand ◽  
3D Printed ◽  
Mouth Guards ◽  
Protective Performance

A multilayer mouth guard is known to have the best protective performance. However, its manufacturing in a digital workflow may be challenging with regards to virtual design and materialization. The present case demonstrates a pathway to fabricate a multilayer individualized mouth guard in a fully digital workflow, which starts with intraoral scanning. A free-form CAD software was used for the virtual design. Two various CAM techniques were used, including Polyjet 3D printing of rubber-like soft material and silicone printing using Drop-on-Demand technique. For both methods the outer layer was manufactured from more rigid materials to facilitate its protective function; the inner layer was printed from a softer material to aid a better adaptation to mucosa and teeth. Both 3D printed multilayer mouth guards showed a clinically acceptable fit and were met with patient appraisal. Their protective capacities must be evaluated in further clinical studies.

scholarly journals Compensating Warpage of 3D Printed Parts Using Free-form Deformation

Procedia CIRP ◽  
2016 ◽  
Vol 41 ◽  
pp. 1017-1022 ◽  
Author(s):  
Christoph Schmutzler ◽  
Alexander Zimmermann ◽  
Michael F. Zaeh
Keyword(s):  
Free Form ◽  
Free Form Deformation ◽  
3D Printed

A Computational Method for the Design of an Additively Manufactured Personalized Artificial Spinal Disc With Physiological Stiffness Under Multiple Loading Conditions

2019 ◽  
Vol 141 (10) ◽  
Author(s):  
Zhiyang Yu ◽  
Kristina Shea ◽  
Tino Stanković
Keyword(s):  
Computational Method ◽  
Free Form ◽  
Material Distribution ◽  
Design Variables ◽  
Spinal Disc ◽  
Variable Reduction ◽  
3D Printed ◽  
Multiple Loading ◽  
Potential Improvement ◽  
Printed Materials

The main limitations of currently available artificial spinal discs are geometric unfit and unnatural motion. Multi-material additive manufacturing (AM) offers a potential solution for the fabrication of personalized free-form implants with a better fit and variable material distribution to achieve a set of target physiological stiffnesses. The structure of the artificial spinal disc proposed in this paper is inspired from a natural disc and includes both a matrix and a crisscross fiber-like structure, where the design variables are their material properties. After carrying out design variable reduction using linking strategies, a finite element-based optimization is then conducted to calculate the optimized material distribution to achieve physiological stiffness under five loading cases. The results show a good match in stiffness of the multi-material disc compared with the natural disc and that the multi-material artificial disc outperforms a current known solution, the ball-and-socket disc. Moreover, the potential of achieving an improved match in stiffness with a larger range of available 3D printable materials is demonstrated. Although the direct surgical implantation of the design is hindered currently by the biocompatibility of the 3D printed materials, a potential improvement of the design proposed is shown.

203 Developing and Fine-Tuning Novel 3D-Printed Biodegradable Scaffolds to Promote Auricular Cartilaginous Regeneration for Surgical Implantation

2021 ◽  
Vol 108 (Supplement_2) ◽  
Author(s):  
A Srivastava ◽  
E Long ◽  
L Wu ◽  
W H Song
Keyword(s):  
Mechanical Properties ◽  
Yield Point ◽  
Cosmetic Surgery ◽  
Maximum Strength ◽  
Fine Tuning ◽  
Free Form ◽  
Element Analysis ◽  
Biodegradable Scaffolds ◽  
Surgical Fixation ◽  
3D Printed

Abstract Introduction Microtia, a congenital cartilaginous defect, poses major challenges in cosmetic surgery. Biodegradable polymers promote chondrogenesis, with promises of seeding cells into synthetic-polymer-implants for surgical fixation. However, existing polymers used in auricular reconstruction present limitations including inflammation, fibrosis, and extrusion. This study aimed to modulate the mechanical properties of the novel polylactic-acid/polyhydroxyalkanoate (PLA/PHA) blend by 3D-printing and hence, evaluate its suitability to the auricular microenvironment in developing next-generation reconstructs. Method Digitally defined PLA/PHA scaffolds were free-form 3D-printed at various infill densities and thicknesses. Through tensile testing, tensile moduli, yield point, maximum strength, tensile toughness, and stiffness were calculated, alongside Finite Element Analysis (FEA) and contact angle tests. Finally, preliminary cell seeding was conducted. Results Increasing infill densities of PLA/PHA scaffolds from 30%-60% significantly increased tensile moduli, yield point and maximum strength (P < 0.01). Tensile stiffness increased significantly with scaffold thicknesses between 1mm-2mm (P < 0.05). Cell studies showed promising proliferative activity. Conclusions The mechanical properties and structural stiffness of 3D-printed PLA/PHA scaffolds can be significantly tailored by altering infill density and thickness, respectively. The digitally defined interconnected pores within printed PLA/PHA scaffolds reduce stiffness mismatches between surgical-synthetic polymers and auricular cartilage, potentially promoting cell migration and nutrition transportation in future reconstructs.

Design and Fabrication of a Thin-Walled Free-Form Scaffold on the Basis of Medical Image Data and a 3D Printed Template: Its Potential Use in Bile Duct Regeneration

2017 ◽  
Vol 9 (14) ◽  
pp. 12290-12298 ◽  
Author(s):  
Suk-Hee Park ◽  
Bo-Kyeong Kang ◽  
Ji Eun Lee ◽  
Seung Woo Chun ◽  
Kiseok Jang ◽  
...  
Keyword(s):  
Bile Duct ◽  
Medical Image ◽  
Image Data ◽  
Free Form ◽  
3D Printed ◽  
Thin Walled ◽  
Medical Image Data ◽  
Potential Use

scholarly journals Micro injection molding of individualised implants using 3D printed molds manufactured via digital light processing

2021 ◽  
Vol 7 (2) ◽  
pp. 399-402
Author(s):  
Robert Mau ◽  
Gábor Jüttner ◽  
Ziwen Gao ◽  
Farnaz Matin ◽  
Dorian Alcacer Labrador ◽  
...  
Keyword(s):  
3D Printing ◽  
Injection Molding ◽  
Round Window ◽  
Free Form ◽  
Micro Injection Molding ◽  
Digital Light Processing ◽  
Liquid Silicone ◽  
3D Printed ◽  
Round Window Niche ◽  
Micro Implants

Abstract Here, we demonstrate a manufacturing process for individualised, small-sized implant prototypes. Our process is promising for the manufacturing of drug-releasing (micro)implants to be implanted in the round window niche (RWN-I, solid body, free-form-shaped design, 1.1 x 2.7 x 3.1 mm) and for frontal neo-ostium implants (FO-I, tube-like design, length ~ 7 mm, Ø ~ 2-6 mm) for frontal sinus drainage. Implant prototypes are manufactured using micro injection molding (μIM). We use digital light processing (DLP) as a 3D printing technique for rapid tooling of accurate molds for the μIM process. A common acrylate-based photopolymer for stiff and high-detailed modelling but with low head deflection temperature of HDT = 60.5 °C is used for DLP 3D printing of the molds. The molds were 3D printed with a layer height of 50 μm in about 20 min (RWN-I) and 60 min (FO-I). For μIM investigations, we use liquid silicone rubber (LSR) as a biocompatible and medically relevant material. Micro injection molding of LSR was investigated using mold temperatures between Tmold = 110 °C (long tcuring ~ 2 h) up to Tmold = 160 °C (short tcuring ~ 5 min). As a result, small-sized, complex-shaped implant prototypes of LSR can be successfully manufactured via μIM using high Tmold = 160 °C and short curing time. DLP 3D printing material with relative low HDT = 60.5 °C was suitable for μIM. There is no significant wear of the molds, when used for a low number of μIM cycles (n ~ 8). Design of metal mold housing has to be suitable (perfect fit of mold, no cavities facing the molds surface for prevention of thermal expansion of mold into cavities).

SURGICAL OUTCOMES OF 3D PRINTED MUSCULOSKELETAL METAL IMPLANTS: A SYSTEMATIC REVIEW

2018 ◽  
Vol 21 (03n04) ◽  
pp. 1840001
Author(s):  
C. Dion ◽  
M. Pollock ◽  
J. Howard ◽  
L. Somerville ◽  
B. Lanting
Keyword(s):  
Systematic Review ◽  
3D Printing ◽  
Surgical Outcomes ◽  
Maxillofacial Surgery ◽  
Case Series ◽  
Free Form ◽  
Bibliographic Databases ◽  
Surgical Practice ◽  
Metal Implants ◽  
3D Printed

Introduction: Additive manufacturing, also known as 3D printing (3DP), is becoming increasingly available to surgeons throughout the world due to recent advancements in technology. 3D printing can produce complex free-form structures that would be impossible using conventional subtractive manufacturing. This offers the possibility to create implants that are better suited to the irregular anatomic shapes found in the human body. The present study aims to examine the surgical outcomes associated with the use of 3D printed metal implants and uncover the value of 3D printing in musculoskeletal surgery. Methods: A systematic review of published literature was performed in June 2017 using the PRISMA protocol. Online bibliographic databases such as MEDLINE, Embase, Scopus, CINAHL, and Cochrane were used to identify studies involving surgical implantation of 3D printed metal implants in musculoskeletal surgery. References from relevant studies were scanned for additional articles. Two reviewers independently screened results. Full-text articles were analyzed for eligibility. A total of 24 studies were included for data abstraction. Results were collected and qualitatively analyzed. Results: Of the 25 articles included, there were 17 case reports, 4 case series, 2 retrospective cohorts and 3 prospective cohorts. Of these articles, the majority of 3DP was done with electron beam melting (EBM) with Ti6Al4V. Orthopaedic, neurosurgical, plastic, and maxillofacial surgery articles were included in the review. All studies concluded that 3D printed implants had favourable post-operative outcomes. Some advantages included the reduction of operative time, improved osseointegration through custom implant porosity, improved fixation, decreased stress shielding, better cosmetic appearance, improved functional outcome, and limb salvage. Additional cost and time required to design and print the implants were reported as potential drawbacks to 3D printing. Discussion/Conclusions. The applications of 3D printing in musculoskeletal surgery are promising and have the potential to alter future surgical practice. However, there is a lack of quality research in the literature assessing the use of 3D printed implants. Further research is needed to evaluate the use of 3D printing in musculoskeletal surgery to understand its potential effects on surgical practice.

Design of freeform gridshell structures – Simplifying the parametric workflow

2019 ◽  
Author(s):  
Steinar Hillersøy Dyvik ◽  
Marcin Luczkowski ◽  
John Haddal Mork ◽  
Anders Nils Rønnquist ◽  
Bendik Manum
Keyword(s):  
Design Process ◽  
Structural Design ◽  
Architectural Design ◽  
Parametric Design ◽  
Efficient Solutions ◽  
Digital Design ◽  
Free Form ◽  
3D Printed ◽  
Set Up ◽  
Design Freedom

<p>Freeform structures can provide both aesthetically interesting and material efficient solutions but are considered a demanding task for both structural design, manufacturing and architectural design. A free form surface is therefore rationalized into something more buildable like the gridshell. However, a digital design process with freeform geometry can be a complex and confusing task. By defining a gridshell as <i>nodes</i>(joints) and <i>elements</i>(members), we can set up a parametric workflow that handles the complexity in design and analysis. Optimization and rationalization of shape, topology, and cross-section are studied real-time, giving the designer confidence and design- freedom. This paper explains a parametric workflow for designing freeform gridshells. Through the design and construction of a timber gridshell pavilion with 3D printed nylon nodes, we discovered important elements of the parametric design process of freeform gridshells.</p>

Glassy free-form 3D micro-optics enabled via ultrafast laser 3D nanolithography

2021 ◽  
Author(s):  
Simonas Varapnickas ◽  
Meguya Ryu ◽  
Darius Gailevicius ◽  
Tai Suzuki ◽  
Greta Merkininkaite ◽  
...  
Keyword(s):  
Ultrafast Laser ◽  
Free Form ◽  
Micro Optics
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