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Smart Materials, Intelligent Structures and Innovative Applications of 3D Printing and Bioprinting Methods

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Biomaterials".

Deadline for manuscript submissions: 20 August 2025 | Viewed by 1707

Special Issue Editors


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Guest Editor
Department of Manufacturing Engineering, Faculty of Industrial Engineering, Robotics and Production Management, Technical University of Cluj-Napoca, 400114 Cluj-Napoca, Romania
Interests: three-dimensional printing; bio-printing; topological optimization; computer aided design; computer aided engineering
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Guest Editor
Faculty of Mechanical Engineering, Institute of Materials Technology, Poznan University of Technology, Poznan, Poland
Interests: CAD/CAM/CAE systems; reverse engineering; 3D printing; virtual reality
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue, titled “Smart Materials, Intelligent Structures and Innovative Applications of 3D Printing and Bioprinting Methods”, aims to publish high-quality and original research papers (papers that have not been published elsewhere) based on innovative research that are mainly related to the evolution and trends of 3D printing methods, with applicability in large areas that are related to medical applications.

The main aim of this Special Issue of Materials is to explore new types of materials that are conceived, developed and suitable to be used for different types of 3D printing technologies. Either we refer to metallic materials, polymers, ceramic materials or composites or refer to specific methods that are used for widening the area of materials (by mixing hybrid materials, coatings, immersing, etc.). The use of these types of materials by using 3D printing methods or bio-printing is aimed to be presented through the papers that will be published in this Special Issue.

Developing different types of lattice structures to decrease the weight of parts by topological optimization (with applicability in the aerospace or automotive industry) or to stimulate the osseo-conductivity of different types of implants made by 3D printing technologies (with applicability in the medical field) are the results that aim to be reached by following different characterization procedures (e.g., mechanical testing, SEM, TEM, AFM, EDX analyses, etc.) in this Special Issue.

In terms of the applicability of the methods, any application that is linked to medical models (skull implant, hip implant, vertebral implant, bone reconstruction, skin, tissue, vessels, muscles, organs, etc.) are more than welcome to be included in the Special Issue.

The main topics of interest encompass  scientific contributions related to the following research areas:

  • New types of materials suitable for 3D printing technologies;
  • Design of new structures and topological optimization;
  • Modeling and simulation of processes or newly developed products;
  • Additive manufacturing, 3D printing and bio-printing methods; Mechanical testing of parts made using 3D printing technologies;
  • Material characterization methods for newly developed materials.

It is our pleasure to invite researchers, scientists, surgeons and professionals from academic institutions and research centers from around the world to submit their contributions to this Special Issue.

Dr. Razvan Ioan Pacurar
Dr. Filip Górski
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing
  • 3D printing
  • bio-printing
  • lattice structures
  • topological optimization
  • bionic design
  • computer aided design
  • finite element analysis
  • smart materials
  • medical implants
  • bone structures
  • osseo-conductivity
  • bio-activity
  • mechanical testing
  • material characterization

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Published Papers (2 papers)

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Research

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14 pages, 5366 KiB  
Article
Influence of the Cortical Layer Thickness and Trabecular Layer Pattern Density on 3D-Printed Femur Strength
by Aleksander Znaczko, Krzysztof Żerdzicki and Paweł Kłosowski
Materials 2025, 18(10), 2187; https://doi.org/10.3390/ma18102187 - 9 May 2025
Viewed by 229
Abstract
This paper presents the process of preparing and conducting a uniaxial compression test, developing the results, and determining the compressive strength of a femur made using 3D printing technology. The study considers the variable thickness of the outer layer—imitating cortical bone tissue—and the [...] Read more.
This paper presents the process of preparing and conducting a uniaxial compression test, developing the results, and determining the compressive strength of a femur made using 3D printing technology. The study considers the variable thickness of the outer layer—imitating cortical bone tissue—and the varying density of the inner layer—imitating trabecular bone tissue—which, with further analysis, may aim to replicate different states of osteoporosis. The compressive strength of the bones varied depending on the thickness of the outer layer and the filling degree. Failure patterns were observed, corresponding to different variants of the produced bones. The predominant failure pattern was the fracture of the femoral head or neck at the proximal end of the femur. The results were compared with previous studies on commercial femur bones, as well as those created using 3D printing technology by other authors. The highest compressive strength was found in the bone with an outer layer thickness of 3.0 mm and 30% infill, with a value of 4778 N. A very similar compressive strength was recorded for the bone with an outer thickness of 2.1 mm and 30% infill, reaching 4519 N. The lowest compressive strength, 2116 N, was observed in the bone with an outer thickness of 1.2 mm and 20% infill. Full article
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Review

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26 pages, 1458 KiB  
Review
The Evolution of Thermoplastic Raw Materials in High-Speed FFF/FDM 3D Printing Era: Challenges and Opportunities
by Antreas Kantaros, Meropi Katsantoni, Theodore Ganetsos and Nicolae Petrescu
Materials 2025, 18(6), 1220; https://doi.org/10.3390/ma18061220 - 9 Mar 2025
Cited by 1 | Viewed by 1255
Abstract
The evolution of thermoplastic materials has played a critical role in advancing high-speed Fused Filament Fabrication (FFF) and Fused Deposition Modeling (FDM) 3D printing technologies. This study explores the performance and challenges associated with next-generation thermoplastics specifically designed for high-speed printing, such as [...] Read more.
The evolution of thermoplastic materials has played a critical role in advancing high-speed Fused Filament Fabrication (FFF) and Fused Deposition Modeling (FDM) 3D printing technologies. This study explores the performance and challenges associated with next-generation thermoplastics specifically designed for high-speed printing, such as high-speed PLA, ABS, and PETG, in comparison to conventional materials. A systematic analysis was conducted to evaluate the key parameters, including the mechanical properties, layer adhesion, surface finish, and dimensional accuracy, under varying high-speed printing conditions. The results reveal that high-speed thermoplastics, when coupled with advanced hardware and optimized motion control systems, achieve up to a 70% reduction in printing time without significant trade-offs in mechanical integrity or precision. Additionally, the study identifies challenges, such as increased thermal stresses, warping, and the need for precise cooling strategies, which can impact material performance at elevated speeds. Opportunities for future development are also discussed, including the design of novel polymer formulations and hardware innovations to further enhance the reliability and scalability of high-speed FFF/FDM printing. This work underscores the potential of adopting such advanced thermoplastic materials in the high-speed 3D printing era and highlights the critical interplay between material science and hardware engineering for achieving next-generation manufacturing capabilities. Full article
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