Search Results (2,106)

Additive manufacturing has emerged as a transformative technology for fabricating complex drug-eluting medical devices, offering unprecedented design freedom and functional integration capabilities. This comprehensive review systematically analyzes 3D printing technologies applied to pharmaceutical device manufacturing, focusing on drug-eluting vascular stents as a representative application. This review covers six primary additive manufacturing techniques, ranging from high-resolution vat photopolymerization (25 μm resolution) to direct energy deposition, with a focus on their capabilities for produce pharmaceutical devices with controlled drug release properties. Novel 4D/5D/6D printing technologies introduce stimuli-responsive behaviors enabling programmable drug release profiles and adaptive device functionality. Manufacturing process optimization reveals superior design flexibility compared to conventional methods, with 85–95% reduction in design iteration time and elimination of tooling costs for complex geometries. The material landscape encompasses traditional metals (316L stainless steel, cobalt–chromium), biodegradable polymers (polylactic acid, PLA; polycaprolactone, PCL; poly(lactic-co-glycolic acid), PLGA), shape-memory materials (i.e., polymers and alloys capable of recovering a pre-programmed shape upon exposure to a specific stimulus such as body temperature, moisture, or light), and advanced nanocomposites, each offering distinct drug-loading capacities (100–500 μg/cm²) and release kinetics. Critical challenges include standardization requirements (International Organization for Standardization (ISO) 5840 and American Society for Testing and Materials (ASTM) F2606), pharmaceutical-grade manufacturing protocols, and regulatory pathways for novel drug-device combinations. This review identifies key research priorities including development of biocompatible printing materials, accelerated drug release testing protocols, and scalable manufacturing processes suitable for medical device production. This analysis demonstrates that 3D printing enables integration of multiple pharmaceutical functions within single devices, controlled spatiotemporal drug delivery, and elimination of secondary manufacturing steps for drug coating processes, advancing the development of next-generation therapeutic medical devices. Full article

Resveratrol (RSV) is a poorly water-soluble polyphenolic compound with various potential health benefits, but its pharmaceutical application is limited by low aqueous solubility and poor oral bioavailability. Additive manufacturing (AM), particularly fused deposition modeling (FDM) 3D printing, offers a flexible approach for fabricating oral dosage forms with customized geometry and internal architecture. In this study, hot-melt extrusion (HME) combined with fused deposition modeling (FDM) 3D printing was used to prepare RSV-loaded tablets with different infill patterns. Hydroxypropyl methylcellulose acetate succinate and hydroxypropyl cellulose were selected as polymeric carriers to prepare RSV-loaded filaments suitable for FDM printing. The effects of infill pattern on the solid-state characteristics, dimensional accuracy, mechanical properties, floating behavior, and in vitro drug release of the printed tablets were systematically investigated. Differential scanning calorimetry, powder X-ray diffraction, and polarized light microscopy indicated that RSV was mainly converted into an amorphous or molecularly dispersed state after HME and FDM processing. All designed tablets were successfully printed and showed acceptable shape fidelity, while different infill patterns resulted in variations in tablet weight, mechanical strength, floating duration, and release behavior. In vitro dissolution studies showed that the RSV release profiles were dependent on the internal infill architecture. Tablets with more complex infill patterns generally exhibited slower drug release, which may be related to differences in internal pore structure, medium penetration pathways, matrix hydration, and diffusion distance. Release kinetic analysis further suggested that RSV release from the printed tablets involved a combination of diffusion and polymer relaxation processes. These results demonstrate that infill pattern is an important structural parameter for modulating the mechanical performance and drug release behavior of FDM 3D-printed RSV tablets. This study provides useful guidance for the design of 3D-printed oral dosage forms with tunable release characteristics. Full article

The rapid growth in the use of carbon fiber-reinforced polymers (CFRPs) and fused-deposition-modeled (FDM) polylactic acid (PLA) has generated substantial non-biodegradable and thermoplastic waste streams, creating urgent needs for scalable recycling and valorization strategies. This study develops and evaluates an integrated route that chemically recovers carbon fibers (CFs) from CFRP waste and converts them into high-performance reinforcements for recycled PLA matrices. CFRP fragments were pre-swollen in acetic acid (120 °C, 1 h), then depolymerized by means of oxidation with 1 M KMnO₄ (100 °C, 2 h), washed, dried (100 °C, 24 h), and size-reduced by means of cryogenic milling. Recycled CFs (treated) and untreated CFRP fragments were blended with 3D-printing PLA waste at 10, 20 and 30 wt.% via melt mixing (175 °C, 5 min, 70 rpm) and molded into ASTM D638 dog-bone specimens. Materials were characterized via XRD, FTIR, Raman, SEM and mechanical testing. XRD and Raman confirmed retention of the graphitic backbone after treatment; FTIR and Raman revealed oxygen-containing surface functionalization consistent with oxidation, while SEM showed effective removal of epoxy and improved fiber surface cleanliness. Compared with neat PLA (tensile strength 45.4 MPa; modulus 2.6 GPa; elongation 6.3%), composites reinforced with chemically recycled CFs exhibited marked mechanical enhancement: at 30 wt.% treated CF, the tensile strength increased to 102.6 MPa (+126%), elastic modulus to 11.7 GPa (+350%), and toughness to 250.3 MPa, while ductility decreased to 2.9%. Equivalent composites with untreated CFRP exhibited smaller gains (30 wt.%: tensile 87.3 MPa; modulus 10.3 GPa), highlighting the benefit of epoxy removal and surface activation for fiber–matrix adhesion. The proposed chemical recycling pathway is operationally simple and cost-effective, produces reusable CFs with preserved graphitic structure and enhanced surface chemistry, and enables the fabrication of high-performance, waste-derived PLA composites suitable for structural and engineering applications. This work demonstrates a viable waste-to-value approach that advances circularity for both CFRP and 3D-printing polymer waste streams. Full article

Polyhydroxyalkanoates (PHAs) are bio-based, biodegradable polyesters increasingly explored as sustainable biomaterials for regenerative medicine. This review summarizes recent advances in PHA-based bone substitute materials, highlighting their properties, fabrication methods, and biological performance. PHAs combine biocompatibility, tunable mechanical behavior, and degradation into non-toxic metabolites, while copolymerization and monomer selection modulate the stiffness, crystallinity, and resorption rate. Processing techniques such as solvent casting, electrospinning, and additive manufacturing allow the production of porous architectures that mimic bone extracellular matrix. Electrospinning is particularly suitable for nanoscale fibrous matrices, whereas 3D printing enables patient-specific scaffolds with controlled geometry and interconnected porosity. Scaffold performance can be further improved through the incorporation of osteoconductive fillers, including hydroxyapatite, β-tricalcium phosphate, bioactive glasses, graphene oxide, and carbon nanotubes, as well as through drug-delivery and pro-angiogenic functionalization. In vitro and in vivo studies consistently report favorable cytocompatibility, enhanced osteogenic differentiation, vascularization, and effective repair of bone defects in animal models. However, clinical translation remains limited by production costs, variability in polymer quality, thermal processing constraints, and regulatory challenges. Future progress will rely on more efficient biosynthesis, medical-grade purification, multifunctional scaffold design, and stronger collaboration between academia, industry, and clinicians to unlock the full potential of PHAs in regenerative bone therapies. Full article

The increasing demand for high-performance and multifunctional polymer materials has driven interest in improving the mechanical properties of polymer components produced through additive manufacturing. This study aims to systematically investigate and comparatively evaluate the effects of low-content nanofiller incorporation on the structural, thermal, and mechanical performance of PLA-based materials produced via fused deposition modeling (FDM), with a focus on identifying filler-dependent behavior under different loading conditions. In this study, polylactic acid (PLA) composites reinforced with 0.5 wt.% graphene (Gr) and 0.5 wt.% silver (Ag) nanoparticles, added separately, were produced using fused deposition modeling (FDM) and comparatively investigated. Each nanofiller was incorporated individually into PLA-based filaments, and standard test specimens were fabricated via 3D printing. Structural, thermal, and mechanical properties were evaluated using tensile, compressive, and three-point bending tests, along with SEM, EDS, XRD, FTIR, DSC, and TGA analyses. The results showed that pure PLA exhibited typical brittle behavior and a single-stage thermal degradation profile. The tensile strength of pure PLA was 41.93 MPa, and the flexural strength was 70.76 MPa. The addition of 0.5 wt.% graphene led to noticeable improvements, particularly in flexural properties, while only a minimal (almost negligible) increase was observed in tensile strength, with tensile strength increasing to 42.24 MPa (+0.74%) and flexural strength increasing to 110.78 MPa (+56.6%). In contrast, 0.5 wt.% Ag exhibited mixed and load-dependent mechanical behavior, with slight improvements in flexural strength but reductions in tensile and compressive properties, where tensile strength decreased to 22.13 MPa (−47.2%) while flexural strength increased to 112.06 MPa (+58.3%). Structural and thermal analyses indicated that both nanofillers did not significantly alter the PLA matrix chemically, while contributing to controlled changes in material properties primarily through physical interactions. The novelty of this work lies in the comparative evaluation of graphene and silver nanoparticle reinforcement at a fixed low loading level within FDM-processed PLA, combined with a comprehensive and correlated analysis of mechanical, structural, and thermal behavior on the same specimen sets, enabling a clearer understanding of filler-dependent performance mechanisms in additively manufactured nanocomposites. Overall, it was concluded that low-rate nanofiller additions, when properly dispersed, may lead to selective improvements in the performance of PLA-based composites depending on filler type and loading mode, and show potential for advanced engineering applications such as lightweight structural components, functional sensors, and additive-manufactured parts requiring tailored mechanical performance and multifunctionality. Full article

Aortic stenosis is predominantly treated through transcatheter bioprosthetic heart valve implantation. However, the materials used in these devices are prone to premature failure. Polymer heart valves provide an alternative to current commercial devices, offering materials with greater durability and customisation through fibre reinforcement. Given the wide range of available materials and structures, there is a need for a systematic and efficient approach to designing and optimising novel bioinspired polymeric leaflets. This work presents a framework that employs computational modelling and Design of Experiments (DOE) tools to optimise bioinspired, 3D-printed, fibre-reinforced polymer leaflets made using melt electrowriting (MEW). Here, finite element (FE) models are created to represent MEW fibre-reinforced polymer leaflets for application in a transcatheter aortic heart valve. The behaviour of this valve under physiological loading conditions is modelled to predict valve performance and leaflet material response. These models were first used to investigate the impact of fibre orientation on valve performance and leaflet response, thereby demonstrating the benefits of a bioinspired fibre reinforcement structure. Using a DOE approach, the structural combination of MEW fibre reinforcement and an elastomeric matrix was optimised to improve valve performance and reduce leaflet stress and strain. Overall, the framework offers an efficient and versatile methodology for optimising fibre-reinforced polymer leaflets using an in silico approach, thereby reducing the need for physical prototyping and testing of these next-generation devices during early product development. Full article

The rapid development of additive manufacturing has enabled the production of personalized biomedical devices, including custom orthoses that must retain their structural integrity under demanding physiological conditions. This study evaluates the performance of 3D-printed polymers—blue and white polylactic acid (PLA), Standard Blue Resin, and an ecological soy-based resin—after exposure to simplified, controlled saline environments related to sweat contact and hygiene-associated conditions. Moisture absorption and Shore A hardness were analyzed as response variables to assess material stability under different experimental conditions. A surface methodology based on a Box–Behnken design was used to quantify the effects of specimen thickness (x₁), NaCl concentration (x₂), and immersion time (x₃) on the selected dependent variables. The results indicate that Standard Blue Resin showed the greatest surface hardness stability, whereas the bio-based materials (PLA and ecological resin) were more susceptible to moisture absorption, particularly in thinner polymeric sheets. The fitted quadratic models provide a predictive framework for optimizing material selection and geometric design in biomimetic wearable devices, supporting the development of orthoses with improved durability, hygiene, and long-term functional performance. Full article

The qualification of additively manufactured (AM) components produced from engineering polymers poses unique challenges, particularly when evaluating mechanical properties according to ASTM D638. The application of high-performance thermoplastics, such as ULTEM™ 9085 and ULTEM™ 1010, frequently relies on manufacturer-provided datasheets for qualification. However, existing datasheets do not provide guidance specific to articles printed in the XY plane, which can be complicated by failures that initiate at microstructural anomalies rather than being driven by intrinsic material behavior. The objective of this study was to investigate the performance and qualification of ULTEM 9085™, examined according to ASTM D638, and pursue improvements through refined print parameters. A significant improvement in strength and conforming failures was achieved with modest adjustments to the print settings. For Type 1 samples printed with ±45° infill, gage section failures improved from only 5% to 100%, while samples with 0/90° infill achieved 80%. Correspondingly, the ultimate tensile strength increased from 49 ± 2 MPa to 61 ± 2 MPa and from 53 ± 3 MPa to 63 ± 6 MPa, respectively. These results underscore the critical role of process parameters, including contour overlap, in qualifying polymer AM materials, and their contribution to the performance and reliability of printed components. Full article

In the present study, the development of a high-density polyethylene/polylactic acid/titanium dioxide (HDPE–PLA–TiO₂) composite proposed for pellet-based additive manufacturing and the evaluation of its thermal and mechanical behavior are presented and discussed. The study was designed to address the printability limitations of high-HDPE-content systems, particularly extrusion instability and weak interlayer adhesion. PLA was introduced to improve processing stability, while TiO₂ was incorporated as an inorganic filler. The selected formulation allowed the production of filaments, pellets, and 3D-printed specimens. Thermal analysis indicated the absence of significant mass loss below approximately 300 °C under the applied thermogravimetric/differential thermal analysis (TG/DTA) conditions, suggesting that no major mass-loss degradation occurred within the selected processing window. However, this result should be interpreted as macroscopic thermal stability and does not exclude possible molecular-level changes in PLA during processing. Tensile tests indicated strengths of 20–25 MPa for extruded filaments and 7.86–10.36 MPa for printed specimens, with an elastic modulus of approximately 2 GPa. Scanning Electron microscopy equipped with Energy Dispersive X-Ray Spectroscopy (SEM/EDS) observations revealed a heterogeneous fracture morphology with cavities, microcracks, fibrillar structures, and local Ti-rich regions, supporting the influence of morphology and filler distribution on the mechanical response of the printed specimens. The results indicate improved printability, adequate thermal behavior for the selected processing conditions, and moderate but reproducible tensile performance, highlighting the potential of this formulation for pellet-based additive manufacturing applications where processability and rigidity are more relevant than maximum tensile strength. Full article

Additively manufactured cellular architectures frequently exhibit brittle failure under impact due to layer-induced stress concentrations. Through the programming of architectural and material design, specifically combining Fused Deposition Modeling (FDM) lattice topology with hyperelastic polyurea infiltration, this study achieves active control over the macroscopic transition from catastrophic structural fragmentation to stable progressive collapse. To evaluate this, auxetic and honeycomb specimens printed with ABS and glass-fiber-reinforced polyamide (PA-GF) were evaluated in unreinforced and polyurea-infiltrated states under quasi-static compression, three-point bending, and Charpy impact loading. Results show that the compressive response depends primarily on cellular topology; the pure auxetic (A-A) configuration provided the highest stiffness and energy absorption. Polyurea infiltration did not significantly alter elastic stiffness but increased post-yield stability, leading to a 96.6% elastic recovery in PA-GF A-A structures. In flexure, the base polymer governed stiffness, with ABS structures measuring 68% stiffer than PA-GF. Unreinforced ABS achieved 34% higher specific energy absorption (SEA) than PA-GF under compression, with the A-H topology maximizing SEA. Under dynamic impact, PA-GF absorbed an average of 70% more energy than ABS, and the H-A configuration recorded the highest impact resistance. The addition of polyurea shifted the failure mode from brittle fragmentation to stable elastomeric deformation, increasing absorbed impact energy by 52% for ABS and over 30% for PA-GF, preventing catastrophic structural failure. Integrating topological sequencing with elastomeric confinement provides a direct method to control energy dissipation and damage tolerance in 3D-printed cellular composites. Full article

Cervical cancer continues to require more precise and clinically adaptable local treatment strategies, particularly in the face of insufficient drug accumulation at the lesion site, systemic toxicity of conventional chemotherapy, limited development of postoperative tissue-interfacing platforms, and the anatomical constraints of standard radiotherapy devices. In this mini-review, we summarize the current landscape of polymer-based biomaterials for local therapy in cervical cancer from both materials and clinical perspectives. Specifically, we discuss three interconnected application domains: local drug delivery systems, polymeric scaffolds and tissue-interfacing platforms, and 3D-printed radiotherapy devices. Recent studies indicate that polymer-based local delivery systems, including nanofiber- and hydrogel-based formulations, can improve cervicovaginal retention, controlled release, and local therapeutic exposure. Scaffold-based systems further extend the role of biomaterials by combining sustained local delivery with defect-specific support and tissue interaction, whereas 3D-printed radiotherapy devices contribute primarily through precision enablement, individualized implantation guidance, and improved conformity in anatomically challenging cases. Despite these advances, most available studies remain preclinical or early translational, and important barriers persist in long-term safety, standardization, clinically relevant validation, and workflow integration. Future progress will depend on application-specific design, stronger translational rigor, and closer integration of biomaterials, imaging, and personalized clinical practice. Full article

Plantar orthoses play an important role in podiatric care, as they help to redistribute plantar loads, improve foot function, and support the treatment of various conditions, including diabetic foot disease. In this context, additive manufacturing has substantially expanded the capacity to produce customized orthoses through digital geometry acquisition, computational design, and controlled fabrication. From a biomimetic and bionic perspective, 3D-printed plantar orthoses can be understood as engineered interfaces that reproduce, support, or modulate key biomechanical functions of the human foot, including load redistribution, shock attenuation, adaptive stiffness, and gait stabilization. Additive manufacturing enables these biological and biomechanical principles to be translated into patient-specific devices through controlled geometry, graded structures, and material selection. Moreover, from a sustainability perspective, recycled polylactic acid (rPLA) has emerged as a material of potential interest for this type of application, not only because of its compatibility with 3D-printing processes but also because it offers the possibility of reusing polymer waste and reducing the consumption of virgin raw materials in devices whose service life may be limited. This review examines the conditional viability of recycled PLA for 3D-printed plantar orthoses by integrating direct clinical evidence on orthotic function with indirect technical evidence from material-level and process-level studies. The reviewed literature indicates that recycled PLA may offer environmental and economic benefits; however, repeated thermomechanical reprocessing may alter viscosity, dimensional consistency, crystallinity, interlayer adhesion, and mechanical reliability. Recent orthosis-focused studies show that extrusion-based technologies can be applied to customized insoles, lattice or internally reinforced structures, multimaterial systems, and emerging smart concepts; however, most of these developments still rely on virgin or ad hoc-designed materials rather than recycled feedstocks. Overall, the available evidence suggests that recycled PLA should not yet be regarded as a direct substitute for virgin PLA in plantar orthoses. At present, the evidence supporting the use of recycled PLA in plantar orthoses is predominantly indirect and technical rather than directly clinical. Its use appears technically promising, but its viability remains conditional and depends on feedstock traceability, control of the manufacturing process, the suitability of material properties for device function, and validation of the orthosis under clinical conditions. Full article

Water-soluble viscosity-modifying admixtures (VMAs) were initially introduced into cementitious materials to enhance cohesion, stability and resistance to bleeding and segregation. With the development of self-compacting concrete, underwater concrete, grouting materials and 3D-printed cementitious materials, VMAs have become increasingly important for regulating rheological behavior, workability retention, shape retention and construction processability. Recent studies further indicate that VMAs can affect not only fresh-state properties, but also hydration kinetics, early-age microstructure evolution, mechanical performance, transport behavior and long-term durability. This review systematically summarizes the types, action mechanisms, and performance effects of water-soluble VMAs in cementitious materials. Particular emphasis is placed on the relationships among the molecular structure, liquid phase viscosity enhancement, particle adsorption and bridging, polymer-chain entanglement, ion-responsiveness, admixture compatibility, and microstructure evolution. The review shows that the effects of VMAs are not governed solely by admixture type or dosage, but depend strongly on molecular mass, functional groups, substituent composition, charge characteristics, binder chemistry, and the pore solution environment. Finally, current research gaps and future directions are discussed, including quantitative structure–mechanism–performance relationships, applicability in low-carbon binders, service-life prediction, and application-oriented VMA design. Full article

Despite major advances in polymer composites for Fused Filament Fabrication (FFF), designing environmentally sustainable materials from bio-based resources remains a key research priority. The objective of this study is to check the processability and properties of sustainable PETG/cork composites processed via FFF technology. Filaments with 5 and 10% of cork were created using a twin-screw extruder. Samples from these filaments were printed by FFF technology, and subsequently subjected to morphological, thermal and mechanical testing. As a result of the study, it was proved that the 3D-printing process did not result in a tensile strength decrease with an increasing cork percentage, as observed in mechanical testing of the filament. The addition of cork significantly increased plasticity without decreasing tensile strength when introducing 10% of cork particles. The interfacial temperatures of the prepared composites did not differ much from the polymer matrix and were 79.55 °C, 77.56 °C, 76.67 °C for PET-G, PET-G + 5% cork, and PET-G + 10% cork, respectively. Thermal conductivity decreased significantly as the percentage of cork increased. This work shows that FFF technology is one of the most suitable manufacturing options for PETG + 10% cork composites to produce things with low conductivity and the same thermal and mechanical properties as pure PETG. Full article

Herein, we report a method to additively manufacture carbon fiber-reinforced siliconized silicon carbide composites. The process involves the pyrolysis of a 3D-printed carbon fiber-reinforced poly-ether-ether-ketone (PEEK) composite to produce a porous carbon fiber-reinforced carbon matrix composite preform, which is subsequently infiltrated with molten silicon to obtain a carbon fiber-reinforced siliconized silicon carbide composite. A key aspect of the method is limiting polymer melt flow during pyrolysis of PEEK, which is achieved by thermally annealing the 3D-printed carbon fiber-reinforced PEEK preform in air at a temperature below PEEK’s melting temperature. Rheological and differential scanning calorimetry (DSC) measurements demonstrate that the thermal annealing treatment altered the melting behavior of PEEK, while NMR and FTIR measurements provided a mechanistic explanation for the structural changes responsible for the behavior. It was also found that dimensional changes during pyrolysis were anisotropic with greater shrinkage in the stacking direction of the material. Full article