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Search Results (830)

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Keywords = 3D-printed sensors

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20 pages, 5799 KB  
Article
Three-Dimensionally Printed Temperature Sensors Based on Conductive PLA Materials
by Agnese Staffa, Gašper Krivic, Mariachiara Tocci, Massimiliano Palmieri, Filippo Cianetti and Janko Slavič
Sensors 2025, 25(20), 6348; https://doi.org/10.3390/s25206348 - 14 Oct 2025
Abstract
Recent innovations in thermoplastic extrusion 3D printing have promoted the development of functional materials, such as conductive composites, which lead the way to the creation of sensors embedded directly into printed structures. To this aim, this paper presents a feasibility study on the [...] Read more.
Recent innovations in thermoplastic extrusion 3D printing have promoted the development of functional materials, such as conductive composites, which lead the way to the creation of sensors embedded directly into printed structures. To this aim, this paper presents a feasibility study on the use of a commercial conductive PLA filament for the realization of a 3D-printed temperature sensor integrated into a thermoplastic structure. To this end, a series of experiments were conducted on 3D-printed samples to analyse the correlation between electrical resistance and temperatures. The results obtained show a clear and reproducible relationship between the two quantities, from which a useful function was derived to estimate the temperature from the resistance measurement. This study confirms the potential of conductive PLA as a low-cost and customisable solution for thermal monitoring and represents a step forward towards the integration of functional sensors through additive manufacturing. Full article
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32 pages, 3888 KB  
Review
AI-Driven Innovations in 3D Printing: Optimization, Automation, and Intelligent Control
by Fatih Altun, Abdulcelil Bayar, Abdulhammed K. Hamzat, Ramazan Asmatulu, Zaara Ali and Eylem Asmatulu
J. Manuf. Mater. Process. 2025, 9(10), 329; https://doi.org/10.3390/jmmp9100329 - 7 Oct 2025
Viewed by 862
Abstract
By greatly increasing automation, accuracy, and flexibility at every step of the additive manufacturing process, from design and production to quality assurance, artificial intelligence (AI) is revolutionizing the 3D printing industry. The integration of AI algorithms into 3D printing systems enables real-time optimization [...] Read more.
By greatly increasing automation, accuracy, and flexibility at every step of the additive manufacturing process, from design and production to quality assurance, artificial intelligence (AI) is revolutionizing the 3D printing industry. The integration of AI algorithms into 3D printing systems enables real-time optimization of print parameters, accurate prediction of material behavior, and early defect detection using computer vision and sensor data. Machine learning (ML) techniques further streamline the design-to-production pipeline by generating complex geometries, automating slicing processes, and enabling adaptive, self-correcting control during printing—functions that align directly with the principles of Industry 4.0/5.0, where cyber-physical integration, autonomous decision-making, and human–machine collaboration drive intelligent manufacturing systems. Along with improving operational effectiveness and product uniformity, this potent combination of AI and 3D printing also propels the creation of intelligent manufacturing systems that are capable of self-learning. This confluence has the potential to completely transform sectors including consumer products, healthcare, construction, and aerospace as it develops. This comprehensive review explores how AI enhances the capabilities of 3D printing, with a focus on process optimization, defect detection, and intelligent control mechanisms. Moreover, unresolved challenges are highlighted—including data scarcity, limited generalizability across printers and materials, certification barriers in safety-critical domains, computational costs, and the need for explainable AI. Full article
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46 pages, 3841 KB  
Systematic Review
From Static to Adaptive: A Systematic Review of Smart Materials and 3D/4D Printing in the Evolution of Assistive Devices
by Muhammad Aziz Sarwar, Nicola Stampone and Muhammad Usman
Actuators 2025, 14(10), 483; https://doi.org/10.3390/act14100483 - 3 Oct 2025
Viewed by 235
Abstract
People with disabilities often face challenges like moving around independently and depending on personal caregivers for daily life activities. Traditional assistive devices are universally accepted by these communities, but they are designed with one-size-fits-all approaches that cannot adjust to individual human sizes, are [...] Read more.
People with disabilities often face challenges like moving around independently and depending on personal caregivers for daily life activities. Traditional assistive devices are universally accepted by these communities, but they are designed with one-size-fits-all approaches that cannot adjust to individual human sizes, are not easily customized, and are made from rigid materials that do not adapt as a person’s condition changes over time. This systematic review examines the integration of smart materials, sensors, actuators, and 3D/4D printing technologies in advancing assistive devices, with a particular emphasis on mobility aids. In this work, the authors conducted a comparative analysis of traditional devices with commercially available innovative prototypes and research stage assistive devices by focusing on smart adaptable materials and sustainable additive manufacturing techniques. The results demonstrate how artificial intelligence drives smart assistive devices in hospital decentralized additive manufacturing, and policy frameworks agree with the Sustainable Development Goals, representing the future direction for adaptive assistive technology. Also, by combining 3D/4D printing and AI, it is possible to produce adaptive, affordable, and patient centered rehabilitation with feedback and can also provide predictive and preventive healthcare strategies. The successful commercialization of adaptive assistive devices relies on cost effective manufacturing techniques clinically aligned development supported by cross disciplinary collaboration to ensure scalable, sustainable, and universally accessible smart solutions. Ultimately, it paves the way for smart, sustainable, and clinically viable assistive devices that outperform conventional solutions and promote equitable access for all users. Full article
(This article belongs to the Section Actuators for Robotics)
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17 pages, 6362 KB  
Article
Development of a 3D-Printed BLDC Motor and Controller for Robotic Applications
by Sangsin Park
Actuators 2025, 14(10), 481; https://doi.org/10.3390/act14100481 - 1 Oct 2025
Cited by 1 | Viewed by 546
Abstract
This paper presents the design and experimental validation of a 3D-printed BLDC motor featuring a hollow-shaft rotor and nickel-reinforced stator. The rotor employs neodymium magnets to reduce inertia while maintaining torque density, and the stator integrates thin nickel laminations to improve flux density. [...] Read more.
This paper presents the design and experimental validation of a 3D-printed BLDC motor featuring a hollow-shaft rotor and nickel-reinforced stator. The rotor employs neodymium magnets to reduce inertia while maintaining torque density, and the stator integrates thin nickel laminations to improve flux density. A custom controller with Hall sensors, BiSS-C encoder, and CAN interface enables closed-loop position control. Experiments demonstrate stable tracking with short settling time and negligible steady-state error, confirming feasibility for robotic and precision applications. Full article
(This article belongs to the Special Issue Power Electronics and Actuators—Second Edition)
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22 pages, 5934 KB  
Article
Enhancing FDM Rapid Prototyping for Industry 4.0 Applications Through Simulation and Optimization Techniques
by Mihalache Ghinea, Alex Cosmin Niculescu and Bogdan Dragos Rosca
Materials 2025, 18(19), 4555; https://doi.org/10.3390/ma18194555 - 30 Sep 2025
Viewed by 368
Abstract
Modern manufacturing is increasingly shaped by the paradigm of Industry 4.0 (Smart Manufacturing). As one of its nine pillars, additive manufacturing plays a crucial role, enabling high-quality final products with improved profitability in minimal time. Advances in this field have facilitated the emergence [...] Read more.
Modern manufacturing is increasingly shaped by the paradigm of Industry 4.0 (Smart Manufacturing). As one of its nine pillars, additive manufacturing plays a crucial role, enabling high-quality final products with improved profitability in minimal time. Advances in this field have facilitated the emergence of diverse technologies—such as Fused Deposition Modelling (FDM), Stereolithography (SLA), and Selective Laser Sintering (SLS)—allowing the use of metallic, polymeric, and composite materials. Within this context, Klipper v.0.12, an open-source firmware for 3D printers, addresses the performance limitations of conventional consumer-grade systems. By offloading computationally intensive tasks to an external single-board computer (e.g., Raspberry Pi), Klipper enhances speed, precision, and flexibility while reducing prototyping time. The purpose of this study is twofold: first, to identify and analyze bottlenecks in low-cost 3D printers and second, to evaluate how these shortcomings can be mitigated through the integration of supplementary hardware and software (Klipper firmware, Raspberry Pi, additional sensors, and the Mainsail interface). The scientific contribution of this study lies in demonstrating that a consumer-grade FDM 3D printer can be significantly upgraded through this integration and systematic calibration, achieving up to a 50% reduction in printing time while maintaining dimensional accuracy and improving surface quality. Full article
(This article belongs to the Section Manufacturing Processes and Systems)
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32 pages, 15768 KB  
Review
Recent Advances in Porous Polymer-Based Flexible Piezoresistive Pressure Sensors
by Junwei Huang, Zhongxin Xu, Jing Zhang, Yujun Wei, Bo Peng, Guanwei Liang and Shudong Yu
Polymers 2025, 17(19), 2584; https://doi.org/10.3390/polym17192584 - 24 Sep 2025
Viewed by 567
Abstract
With the rapid development of wearable devices and intelligent human–machine interaction technologies, the demand for high-precision pressure sensors has soared. Piezoresistive pressure sensors excel due to their simple structure, low cost, and high sensitivity, among which flexible piezoresistive pressure sensors based on porous [...] Read more.
With the rapid development of wearable devices and intelligent human–machine interaction technologies, the demand for high-precision pressure sensors has soared. Piezoresistive pressure sensors excel due to their simple structure, low cost, and high sensitivity, among which flexible piezoresistive pressure sensors based on porous polymers have become a research focus, thanks to their unique 3D porous structure and excellent performance. This review summarizes recent advances: it introduces key performance metrics and the piezoresistive sensing mechanism; outlines porous structure preparation methods (phase separation, 3D printing, electrospinning) with their principles, advantages, and limitations; examines conductive fillers (carbon-based, polymer, metal, MXene) with their properties and applications; and highlights flexible substrates (silicone, polyurethane, polyimide, natural polymers) in ensuring mechanical compliance and device integration. Studies show material innovation, structural optimization, and process improvement can significantly enhance sensor accuracy, stability, and durability, helping break traditional performance bottlenecks. Future prospects are broad in tactile sensing, biomedical monitoring, and human–machine interaction, providing references for related research and industrial development. Full article
(This article belongs to the Special Issue Porous Polymers: Preparation, Characterization and Applications)
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29 pages, 7962 KB  
Article
Design and Validation of a Compact, Low-Cost Sensor System for Real-Time Indoor Environmental Monitoring
by Vincenzo Di Leo, Alberto Speroni, Giulio Ferla and Juan Diego Blanco Cadena
Buildings 2025, 15(19), 3440; https://doi.org/10.3390/buildings15193440 - 23 Sep 2025
Viewed by 472
Abstract
The growing interest in smart buildings and the integration of IoT-based technologies is driving the development of new tools for monitoring and optimizing indoor environmental quality (IEQ). However, many existing solutions remain expensive, invasive and inflexible. This paper presents the design and validation [...] Read more.
The growing interest in smart buildings and the integration of IoT-based technologies is driving the development of new tools for monitoring and optimizing indoor environmental quality (IEQ). However, many existing solutions remain expensive, invasive and inflexible. This paper presents the design and validation of a compact, low-cost, and real-time sensor system, conceived for seamless integration into indoor environments. The system measures key parameters—including air temperature, relative humidity, illuminance, air quality, and sound pressure level—and is embeddable in standard office equipment with minimal impact. Leveraging 3D printing and open-source hardware/software, the proposed solution offers high affordability (approx. EUR 33), scalability, and potential for workspace retrofits. To assess the system’s performance and relevance, dynamic simulations were conducted to evaluate metrics such as the Mean Radiant Temperature (MRT) and illuminance in an open office layout. In addition, field tests with a functional prototype enabled model validation through on-site measured data. The results highlighted significant local discrepancies—up to 6.9 °C in MRT and 28 klx in illuminance—compared to average conditions, with direct implications for thermal and visual comfort. These findings demonstrate the system’s capacity to support high-resolution environmental monitoring within IoT-enabled buildings, offering a practical path toward the data-driven optimization of occupant comfort and energy efficiency. Full article
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24 pages, 1518 KB  
Article
Smart Matter-Enabled Air Vents for Trombe Wall Automation and Control
by Gabriel Conceição, Tiago Coelho, Afonso Mota, Ana Briga-Sá and António Valente
Electronics 2025, 14(18), 3741; https://doi.org/10.3390/electronics14183741 - 22 Sep 2025
Viewed by 665
Abstract
Improving energy efficiency in buildings is critical for supporting sustainable growth in the construction sector. In this context, the implementation of passive solar solutions in the building envelope plays an important role. Trombe wall is a passive solar system that presents great potential [...] Read more.
Improving energy efficiency in buildings is critical for supporting sustainable growth in the construction sector. In this context, the implementation of passive solar solutions in the building envelope plays an important role. Trombe wall is a passive solar system that presents great potential for passive solar heating purposes. However, its performance can be enhanced when the Internet of Things is applied. This study employs a multi-domain smart system based on Matter-enabled IoT technology for maximizing Trombe wall functionality using appropriate 3D-printed ventilation grids. The system includes ESP32-C6 microcontrollers with temperature sensors and ventilation grids controlled by actuated servo motors. The system is automated with a Raspberry Pi 5 running Home Assistant OS with Matter Server. The integration of the Matter protocol provides end-to-end interoperability and secure communication, avoiding traditional systems based on MQTT. This work demonstrates the technical feasibility of implementing smart ventilation control for Trombe walls using a Matter-enabled infrastructure. The system proves to be capable of executing real-time vent management based on predefined temperature thresholds. This setup lays the foundation for scalable and interoperable thermal automation in passive solar systems, paving the way for future optimizations and addicional implementations, namely in order to improve indoor thermal comfort in smart and more efficient buildings. Full article
(This article belongs to the Special Issue Parallel and Distributed Computing for Emerging Applications)
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36 pages, 2691 KB  
Review
Advanced Electrochemical Sensors for Rapid and Sensitive Monitoring of Tryptophan and Tryptamine in Clinical Diagnostics
by Janani Sridev, Arif R. Deen, Md Younus Ali, Wei-Ting Ting, M. Jamal Deen and Matiar M. R. Howlader
Biosensors 2025, 15(9), 626; https://doi.org/10.3390/bios15090626 - 19 Sep 2025
Viewed by 1003
Abstract
Tryptophan (Trp) and tryptamine (Tryp), critical biomarkers in mood regulation, immune function, and metabolic homeostasis, are increasingly recognized for their roles in both oral and systemic pathologies, including neurodegenerative disorders, cancers, and inflammatory conditions. Their rapid, sensitive detection in biofluids such as saliva—a [...] Read more.
Tryptophan (Trp) and tryptamine (Tryp), critical biomarkers in mood regulation, immune function, and metabolic homeostasis, are increasingly recognized for their roles in both oral and systemic pathologies, including neurodegenerative disorders, cancers, and inflammatory conditions. Their rapid, sensitive detection in biofluids such as saliva—a non-invasive, real-time diagnostic medium—offers transformative potential for early disease identification and personalized health monitoring. This review synthesizes advancements in electrochemical sensor technologies tailored for Trp and Tryp quantification, emphasizing their clinical relevance in diagnosing conditions like oral squamous cell carcinoma (OSCC), Alzheimer’s disease (AD), and breast cancer, where dysregulated Trp metabolism reflects immune dysfunction or tumor progression. Electrochemical platforms have overcome the limitations of conventional techniques (e.g., enzyme-linked immunosorbent assays (ELISA) and mass spectrometry) by integrating innovative nanomaterials and smart engineering strategies. Carbon-based architectures, such as graphene (Gr) and carbon nanotubes (CNTs) functionalized with metal nanoparticles (Ni and Co) or nitrogen dopants, amplify electron transfer kinetics and catalytic activity, achieving sub-nanomolar detection limits. Synergies between doping and advanced functionalization—via aptamers (Apt), molecularly imprinted polymers (MIPs), or metal-oxide hybrids—impart exceptional selectivity, enabling the precise discrimination of Trp and Tryp in complex matrices like saliva. Mechanistically, redox reactions at the indole ring are optimized through tailored electrode interfaces, which enhance reaction kinetics and stability over repeated cycles. Translational strides include 3D-printed microfluidics and wearable sensors for continuous intraoral health surveillance, demonstrating clinical utility in detecting elevated Trp levels in OSCC and breast cancer. These platforms align with point-of-care (POC) needs through rapid response times, minimal fouling, and compatibility with scalable fabrication. However, challenges persist in standardizing saliva collection, mitigating matrix interference, and validating biomarkers across diverse populations. Emerging solutions, such as AI-driven analytics and antifouling coatings, coupled with interdisciplinary efforts to refine device integration and manufacturing, are critical to bridging these gaps. By harmonizing material innovation with clinical insights, electrochemical sensors promise to revolutionize precision medicine, offering cost-effective, real-time diagnostics for both localized oral pathologies and systemic diseases. As the field advances, addressing stability and scalability barriers will unlock the full potential of these technologies, transforming them into indispensable tools for early intervention and tailored therapeutic monitoring in global healthcare. Full article
(This article belongs to the Special Issue Nanomaterial-Based Biosensors for Point-of-Care Testing)
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36 pages, 3444 KB  
Review
Next-Generation Smart Carbon–Polymer Nanocomposites: Advances in Sensing and Actuation Technologies
by Mubasshira, Md. Mahbubur Rahman, Md. Nizam Uddin, Mukitur Rhaman, Sourav Roy and Md Shamim Sarker
Processes 2025, 13(9), 2991; https://doi.org/10.3390/pr13092991 - 19 Sep 2025
Cited by 2 | Viewed by 689
Abstract
The convergence of carbon nanomaterials and functional polymers has led to the emergence of smart carbon–polymer nanocomposites (CPNCs), which possess exceptional potential for next-generation sensing and actuation systems. These hybrid materials exhibit unique combinations of electrical, thermal, and mechanical properties, along with tunable [...] Read more.
The convergence of carbon nanomaterials and functional polymers has led to the emergence of smart carbon–polymer nanocomposites (CPNCs), which possess exceptional potential for next-generation sensing and actuation systems. These hybrid materials exhibit unique combinations of electrical, thermal, and mechanical properties, along with tunable responsiveness to external stimuli such as strain, pressure, temperature, light, and chemical environments. This review provides a comprehensive overview of recent advances in the design and synthesis of CPNCs, focusing on their application in multifunctional sensors and actuator technologies. Key carbon nanomaterials including graphene, carbon nanotubes (CNTs), and MXenes were examined in the context of their integration into polymer matrices to enhance performance parameters such as sensitivity, flexibility, response time, and durability. The review also highlights novel fabrication techniques, such as 3D printing, self-assembly, and in situ polymerization, that are driving innovation in device architectures. Applications in wearable electronics, soft robotics, biomedical diagnostics, and environmental monitoring are discussed to illustrate the transformative impact of CPNCs. Finally, this review addresses current challenges and outlines future research directions toward scalable manufacturing, environmental stability, and multifunctional integration for the real-world deployment of smart sensing and actuation systems. Full article
(This article belongs to the Special Issue Polymer Nanocomposites for Smart Applications)
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20 pages, 5106 KB  
Article
3D-Printed Wearable Sensors for the Identification of Shoulder Movement Planes
by Alfredo Dimo, Umile Giuseppe Longo, Pieter D’Hooghe, Alessandro de Sire, Rocco Papalia, Emiliano Schena and Daniela Lo Presti
Sensors 2025, 25(18), 5853; https://doi.org/10.3390/s25185853 - 19 Sep 2025
Viewed by 518
Abstract
Rotator cuff injuries are a leading cause of shoulder disability, directly impacting joint mobility and overall quality of life. Effective recovery in these patients depends not only on surgical intervention, when necessary, but also on accurate and continuous monitoring of joint movements during [...] Read more.
Rotator cuff injuries are a leading cause of shoulder disability, directly impacting joint mobility and overall quality of life. Effective recovery in these patients depends not only on surgical intervention, when necessary, but also on accurate and continuous monitoring of joint movements during rehabilitation, especially across multiple anatomical planes. Traditional tools, such as clinical assessments or motion capture systems, are often subjective or expensive and impractical for routine use. In this context, wearable devices are emerging as a viable alternative, offering the ability to collect real-time, non-invasive, and repeatable data, both in clinical and home settings. This study presents innovative wearable sensors, developed through 3D printing and integrated with fiber Bragg grating technology, designed to detect the shoulder’s planes of motion (sagittal, scapular, and frontal) during flexion–extension movements. Two wearable sensors made of thermoplastic polyurethane (TPU 85A and 95A) were fabricated and subjected to metrological characterization, including strain and temperature sensitivity, hysteresis error, and tear resistance, and tested on eight healthy volunteers. The results demonstrated high discriminative ability, with sensitivity values up to 0.76 nm/mε and low hysteresis errors. The proposed system represents a promising, cost-effective, and customizable solution for motion monitoring during shoulder rehabilitation. Full article
(This article belongs to the Special Issue Wearable Systems for Monitoring Joint Kinematics)
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18 pages, 20480 KB  
Article
Design of a PEBA–Silicone Composite Magneto-Sensitive Airbag Sensor for Simultaneous Contact Force and Motion Detection
by Zhirui Zhao, Chun Xia, Xinyu Zeng, Xinyu Hou, Lina Hao, Dexing Shan and Jiqian Xu
Sensors 2025, 25(18), 5823; https://doi.org/10.3390/s25185823 - 18 Sep 2025
Viewed by 450
Abstract
Considering that soft airbag sensors made from soft materials are limited to detecting only normal forces, a novel PEBA–silicone composite magneto-sensitive airbag sensor is proposed for simultaneously detecting normal contact force and horizontal motion during human–robot interaction. In terms of structural design, the [...] Read more.
Considering that soft airbag sensors made from soft materials are limited to detecting only normal forces, a novel PEBA–silicone composite magneto-sensitive airbag sensor is proposed for simultaneously detecting normal contact force and horizontal motion during human–robot interaction. In terms of structural design, the PEBA–silicone composite airbag is manufactured using fused deposition modeling, 3D printing, and silicone casting, achieving a balance between high airtightness and adjustable stiffness. Beneath the airbag, a magneto-sensitive substrate with several NdFeB magnets is embedded, while a fixed Hall sensor detects spatially varying magnetic fields to determine horizontal displacements without contact. The results of contact-force and motion experiments show that the proposed sensor achieves a force resolution of 20 g, a force range of 0 to 1100 g, a fitting sensitivity of 7.54 N/Pa, an average static stiffness of 4.82 N/mm, and a horizontal motion detection range of 0.125 to 1 cm/s. In addition, the prototype of the sensor is lightweight (with the complete assembly weighing 81.25 g and the sensing part weighing 56.13 g) and low-cost, giving it potential application value in exoskeletons and industrial grippers. Full article
(This article belongs to the Section Sensors and Robotics)
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14 pages, 505 KB  
Article
Experimental Setup for the Validation of Photoplethysmography Devices for the Evaluation of Arteriovenous Fistulas
by Simone Chiorboli, Adriano Brugnoli and Vincenzo Piemonte
Bioengineering 2025, 12(9), 990; https://doi.org/10.3390/bioengineering12090990 - 18 Sep 2025
Viewed by 472
Abstract
This study describes the design and validation of an experimental setup for testing photoplethysmographic (PPG) devices intended for the non-invasive monitoring of vascular accesses in hemodialysis patients. Continuous assessment of arteriovenous fistulas is essential to detect pathological conditions such as stenosis, which can [...] Read more.
This study describes the design and validation of an experimental setup for testing photoplethysmographic (PPG) devices intended for the non-invasive monitoring of vascular accesses in hemodialysis patients. Continuous assessment of arteriovenous fistulas is essential to detect pathological conditions such as stenosis, which can compromise patient safety and dialysis efficacy. While PPG-based sensors are capable of detecting such anomalies, their clinical applicability must be supported by controlled in vitro validation. The developed system replicates the anatomical, mechanical, optical, and hemodynamic features of vascular accesses. A 3D fistula model was designed and fabricated via 3D printing and silicone casting. The hydraulic circuit used red India ink and a PWM-controlled pump to simulate physiological blood flow, including stenotic conditions. Quantitative validation confirmed anatomical accuracy within 0.1 mm tolerance. The phantom exhibited an average Shore A hardness of 20.3 ± 1.1, a Young’s modulus of 10.4 ± 0.9 MPa, and a compression modulus of 105 MPa—values consistent with soft tissue behavior. Burst pressure exceeded 2000 mmHg, meeting ISO 7198:2016 standards. Flow rates (400–700 mL/min) showed <1% error. Compliance was 2.4 ± 0.2, and simulated blood viscosity was 3.9 ± 0.3 mPa·s. Systolic and diastolic pressures fell within physiological ranges. Photoplethysmographic signals acquired using a MAX30102 sensor (Analog devices Inc., Wilmington, MA, USA) reproduced key components of in vivo waveforms, confirming the system’s suitability for device testing. Full article
(This article belongs to the Section Biomedical Engineering and Biomaterials)
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21 pages, 5918 KB  
Review
Innovations in Orthotic Devices: Additive Manufacturing, Auxetic Materials and Smart Sensors for Enhanced Rehabilitation
by Riccardo Carlo Moroni and Katarzyna Majewska
Appl. Sci. 2025, 15(18), 10167; https://doi.org/10.3390/app151810167 - 18 Sep 2025
Viewed by 838
Abstract
Orthoses are external devices designed to provide structural and functional support for disorders affecting the musculoskeletal or nervous systems. While these devices have a long history, recent technological advancements offer significant opportunities to enhance their therapeutic performance. This review examines three key innovations [...] Read more.
Orthoses are external devices designed to provide structural and functional support for disorders affecting the musculoskeletal or nervous systems. While these devices have a long history, recent technological advancements offer significant opportunities to enhance their therapeutic performance. This review examines three key innovations shaping the future of orthotic devices: additive manufacturing, auxetic metamaterials, and smart sensors. Additive manufacturing (AM), commonly known as 3D printing, is gaining prominence for its ability to create patient-specific solutions, improve design flexibility, and reduce production time. Despite these advantages, traditional fabrication methods remain dominant due to cost and regulatory challenges. Auxetic metamaterials, characterized by a negative Poisson’s ratio, allow an orthosis to dynamically conform to the patient’s anatomy and movements while maintaining stability and comfort. Thanks to synclastic deformation, auxetic structures reduce the formation of wrinkles during motion, improving body fit, and potentially enhancing comfort as well as adherence to orthosis usage recommendations. However, their integration into orthoses is still in the early stages, requiring further research and clinical validation. Finally, smart sensors have been extensively studied for the real-time monitoring of joint movement and rehabilitation progress, enabling personalized therapy and improved clinical outcomes. In conclusion, these emerging technologies—additive manufacturing, auxetic metamaterials, and smart sensors—hold great promise for next-generation orthotic devices, but widespread adoption will depend on addressing technical, economic, and practical limitations. Full article
(This article belongs to the Special Issue Recent Progress and Challenges of Digital Health and Bioengineering)
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26 pages, 3077 KB  
Review
A Point-Line-Area Paradigm: 3D Printing for Next-Generation Health Monitoring Sensors
by Mei Ming, Xiaohong Yin, Yinchen Luo, Bin Zhang and Qian Xue
Sensors 2025, 25(18), 5777; https://doi.org/10.3390/s25185777 - 16 Sep 2025
Viewed by 496
Abstract
Three-dimensional printing technology is fundamentally reshaping the design and fabrication of health monitoring sensors. While it holds great promise for achieving miniaturization, multi-material integration, and personalized customization, the lack of a clear selection framework hinders the optimal matching of printing technologies to specific [...] Read more.
Three-dimensional printing technology is fundamentally reshaping the design and fabrication of health monitoring sensors. While it holds great promise for achieving miniaturization, multi-material integration, and personalized customization, the lack of a clear selection framework hinders the optimal matching of printing technologies to specific sensor requirements. This review presents a classification framework based on existing standards and specifically designed to address sensor-related requirements, categorizing 3D printing technologies into point-based, line-based, and area-based modalities according to their fundamental fabrication unit. This framework directly bridges the capabilities of each modality, such as nanoscale resolution, multi-material versatility, and high-throughput production, with the critical demands of modern health monitoring sensors. We systematically demonstrate how this approach guides technology selection: Point-based methods (e.g., stereolithography, inkjet) enable micron-scale features for ultra-sensitive detection; line-based techniques (e.g., Direct Ink Writing, Fused Filament Fabrication) excel in multi-material integration for creating complex functional devices such as sweat-sensing patches; and area-based approaches (e.g., Digital Light Processing) facilitate rapid production of sensor arrays and intricate structures for applications like continuous glucose monitoring. The point–line–area paradigm offers a powerful heuristic for designing and manufacturing next-generation health monitoring sensors. We also discuss strategies to overcome existing challenges, including material biocompatibility and cross-scale manufacturing, through the integration of AI-driven design and stimuli-responsive materials. This framework not only clarifies the current research landscape but also accelerates the development of intelligent, personalized, and sustainable health monitoring systems. Full article
(This article belongs to the Section Electronic Sensors)
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