Search Results (78)

This study evaluates the rapid tooling feasibility and structural significance of utilizing digital light processing (DLP)-printed alumina as a near-net-shape ceramic mold-insert preform route for replication of curved polymer optics. While conventional production tooling for precision optics demands immediate optical-grade tolerances, the fundamental mechanisms governing polymer replication close to additively manufactured ceramic interfaces remain insufficiently understood. To isolate these multi-factor processing signatures, alumina specimens incorporating concave and convex parabolic surfaces were synthesized via lithography-based ceramic manufacturing. Our design acts as a geometric control lens, ensuring that thermal shrinkage trends, slicing kinematics, and interfacial replication behaviors are clearly exposed and quantified under uniform boundary conditions. Following debinding and sintering, exploratory hot-pressing cycles were executed to evaluate gross profile transfer and surface inheritance on poly(methyl methacrylate) (PMMA) replicas. Quantitative laser scanning confocal microscopy confirmed successful gross curvature generation and revealed geometry-dependent post-sintering shrinkage trends. The convex inserts exhibited an average peak-to-valley (PV) error of 123.48 ± 3.30 µm and an RMS error of 29.76 ± 1.23 µm, whereas the concave alumina inserts showed an average PV error of 137.98 ± 5.80 µm and an RMS error of 34.68 ± 1.20 µm. The PMMA replicas also showed substantial form deviation, with an average PV error of 163.72 ± 15.64 µm and RMS error of 27.37 ± 2.03 µm. Our work presents a route for producing near-net-shape ceramic mold-insert preforms that transforms complex processing variations into a predictable, mathematically addressable roadmap. A geometry-specific CAD pre-compensation can then be performed while the remaining precision gap can be selectively closed via targeted post-polishing depending on the desired optical application tier. Full article

Parallel shield tunneling in close proximity to existing metro tunnels induces additional settlement deformation of existing structures, which poses a challenge to operational safety. In this paper, a self-developed Φ200 mm model shield machine test system is adopted to carry out model test research on the settlement response of existing tunnels induced by parallel symmetric shield tunneling. A 1:30-scaled 3D-printed refined assembled segment model is fabricated based on similarity theory, and high-precision distributed optical fiber sensing technology is used for deformation monitoring. The influences of vertical spacing of tunnels, center spacing of new tunnels, axis angle and stratum loss rate on the settlement of existing tunnels are analyzed. The results show that the settlement curve of the existing tunnel arch presents a normal distribution shape, and the maximum settlement occurs near the new tunnel side. The settlement of existing tunnels decreases with the increase in vertical spacing between new and existing tunnels, and increases with the increase in stratum loss rate and center spacing of new tunnels. The research results can provide experimental support for safety control of parallel shield tunnel construction. Full article

Compliant mechanisms have contributed to many advances in soft robotics, and there is strong motivation to translate these ideas to assistive devices where adaptive motion at the human interface is required. This work presents novel reconfigurable compliant joints (RCJs) as a parameterized joint element for functional biomimicry in lower-extremity joints for prosthetic knees and ankle–foot orthoses, with concepts that extend to other limb joints. The RCJ uses a rigid hub and outer ring joined by an array of flexible links with centerlines defined by cubic Bézier curves. Link shapes are organized into four Bézier classes (A–D), with base types using 10, 12, or 14 uniformly distributed link slots and variants generated by modifying active-link count and distribution, forming a structured morphology space of 12 configurations for machine design. Dual-extrusion 3D-printed prototypes are characterized by a custom testing apparatus using a 2.2 kN load cell at 25 mm/s over a 0–90° rotation range across six recorded load cycles to measure torque–angle curves and stiffness under large deformations. Angle-dependent stiffness is evaluated over three fixed intervals (0–30°, 30–60°, and 60–90°) to quantify multi-stage behavior. A 2-dimensional corotational frame model and a Simscape Multibody model, including a rolling-contact knee configuration, use the same parameterization to relate geometry, nonlinear mechanics, and system-level motion. Experiments and simulations show multi-stage torque–angle profiles and predictable stiffness modulation across all configurations, with both magnitude and transition angle tunable through Bézier class and active-link distribution, positioning the RCJ as a CAD/CAE-compatible joint architecture for assistive devices or wearable robotic systems and a basis for advancing functional biomimicry in compliant mechanism design. Full article

This study proposes a novel semi-discrete model of non-ordinary state-based peridynamics. It is used to simulate the tensile failure process of dog bone-shaped specimens of 3D-printed fiber-reinforced concrete with 0%, 1% and 2% fiber volume fractions. The results are compared with the literature laboratory results to verify the feasibility and reliability of the approach. In addition, it is utilized for a 3D-printable engineered cement-based composite (ECC) disk splitting simulation. Effects of different fiber lengths, printing interfaces, and fiber orientations on the failure process of disc specimens are investigated. It is found that ductile failure appears in the loading direction, while brittle failure appears in the other direction. Effect of fiber length on the bearing capacity is feeble. In addition, the non-ordinary state-based peridynamics semi-discrete model is used to simulate the crack propagation of three-point bending. The principal stress contours, damage diagrams, and displacement–load curves of the concrete matrix at different time steps during the crack propagation process are obtained. The simulation is in great agreement with the experimental results. Finally, it is demonstrated that the novel non-ordinary state-based peridynamics approach proposed in this paper is accurate and efficient to simulate fracture behavior of 3D-printed ECC beams. Full article

This review develops a materials-to-clinic framework for patient-specific, functionally graded (FG) NiTi shape memory alloy (SMA) rods as a complementary paradigm for scoliosis correction that targets durable alignment with motion preservation. The article synthesizes the thermomechanical basis of NiTi (thermoelastic martensitic transformation, near constant superelastic plateau, and hysteretic damping) while leveraging additive manufacturing (AM) capabilities to spatially program transformation temperatures (e.g., A_f), effective stiffness, and geometric inertia along the rod. Consolidated process–structure–property linkages are provided for the PBF-LB, DED, and BJAM routes, together with contamination and composition-control strategies (mitigation of Ni volatilization; management of O/C uptake; gradient heat treatments) and segment-level quality assurance (DSC mapping, micro-CT, EBSD/indentation, and bench bending/torsion in physiologic media). Building on clinical curve classification, the methodology formalizes a grading mask and target moment vector that drive multi-objective optimization of the segmental A_f, relative density/architecture, and cross-section, followed by route-specific build plans and acceptance tolerances. A phenomenological constitutive description provides the forward map from local design variables to temperature-dependent moment–curvature loops for finite element verification and uncertainty control. Surgical handling and activation policies are codified (cold shaping in martensite and controlled intra-/postoperative warming within tissue-safe bounds), and a translational roadmap is outlined, encompassing prospective calibration of classification-to-design mappings, AM process maps with in situ monitoring, digital twin planning, and long-horizon fatigue/corrosion protocols. The proposed graded structures provide an adaptive transformation temperature gradient and tunable mechanical response, representing an important design direction toward 3D-printed, patient-specific SMA rods for durable, adjustable, and efficient scoliosis correction. Full article

Background: Intervertebral disc degeneration is a prevalent condition and a major risk factor for disc herniation. Mechanical overload, aging, injury, and disease contribute to the annulus fibrosus’ structural failure, which allows nucleus pulposus material to escape and reduces the capacity to absorb shock. This study builds on previous investigations by evaluating additional thermoplastic polyurethane (TPU) filaments as potential materials for additively manufactured intervertebral disc replacements. Materials and Methods: Disc-shaped specimens (Ø50 × 10 mm) were fabricated using fused deposition modeling (FDM). A gyroid infill structure was employed with unit cell sizes ranging from 4 to 10 mm³ and wall thicknesses between 0.5 and 1.0 mm. The outer wall thickness varied from 0.4 to 0.8 mm. Four TPU filaments (Extrudr FlexSemiSoft, GEEE-TECH TPU, SUNLU TPU, and OVERTURE TPU) were tested, resulting in 36 parameter combinations per filament. Printed discs were examined via stereomicroscopy. Tensile testing was conducted according to DIN EN ISO 527-1 using Type 5A specimens. Mechanical performance under physiological loading was assessed through uniaxial compression tests, in which samples were compressed to 50% of their height while force–deformation curves were recorded. Target forces were defined as 4000–7500 N to maintain comparability with prior studies. Results: Across all filaments, a maximum of three parameter combinations per material achieved forces within the target range. Microscopy confirmed the dimensional accuracy of wall thicknesses with minimal deviation. Tensile strength values for GEEE-TECH, SUNLU, and FlexSemiSoft were comparable (10–11 MPa), while OVERTURE showed significantly lower strength (approximately 9 MPa). Tensile modulus values followed a similar trend: 25–30 MPa for three filaments and 17.5 MPa for OVERTURE. Conclusions: All four TPU filaments could be used to fabricate discs that met the mechanical requirements for compression. These results confirm that both the tested TPU materials and gyroid structures are suitable for potential intervertebral disc replacement applications. Full article

Rheology plays an important role in the 3D concrete printing technology, because it directly governs the flowability and shape retention of the material, impacting both the printing process and the final quality of the obtained structure. Local raw materials such as Portland cement, washed sand, and tap water were used for the preparation of 3D-printed concrete mixtures. The solid-state polycarboxylate ether with an anti-foaming agent was used as superplasticizer. The Portland cement was partially replaced (by volume) with a natural zeolite additive in amounts ranging from 0% to 9% in 3D-printed concrete mixtures. A rotational rheometer with coaxial cylinders was used in this research for the determination of rheological characteristics of prepared 3D-printed concrete mixtures. The Herschel–Buckley model was used to approximate experimental flow curves and assess rheological parameters such as yield stress, plastic viscosity, and shear-thinning/thickening index. The additional experiments and calculations, such as water bleeding test and evaluation of the carbon footprint of 3D-printed concrete mixtures, were performed in this work. The replacement of Portland cement with natural zeolite additive positively influenced rheological and stability-related properties of 3D-printed concrete mixtures. Natural zeolite additive consistently reduced water bleeding, enhanced yield stress under increasing shear rates, and lowered plastic viscosity, thereby improving flowability and mixture transportation during the 3D printing process. As the shear-thinning/thickening index remained stable (indicating non-thixotropic behavior in most cases), higher amounts of natural zeolite additive introduced slight thixotropy (especially under decreased shear rates). These changes contributed to better shape retention, layer stability, and the ability to print taller and narrower structures without collapse, making natural zeolite additive suitable for use in the optimized processes of 3D concrete printing. A significant decrease in total carbon footprint (from 3% to 19%) was observed in 3D-printed concrete mixtures with an increase in the mentioned amounts of natural zeolite additive, compared to the mixture without this additive. Full article

A biomimetic cartilage scaffold featuring a continuous hydroxyapatite (HA) concentration gradient and a spatially curved architecture was developed using a dual-channel mixing extrusion-based 3D printing approach. By dynamically regulating the feeding rates of two bioinks during printing, a continuous HA gradient decreasing from the bottom to the top of the scaffold was precisely achieved, mimicking the compositional transition from the calcified to the non-calcified cartilage region in native articular cartilage. The integration of gradient material deposition with synchronized multi-axis motion enabled accurate fabrication of curved geometries with high structural fidelity. The printed scaffolds exhibited stable swelling and degradation behavior and showed improved compressive performance compared with step-gradient counterparts. Rheological analysis confirmed that the bioinks possessed suitable shear-thinning and recovery properties, ensuring printability and shape stability during extrusion. In vitro evaluations demonstrated good cytocompatibility, supporting bone marrow mesenchymal stem cell (BMSC) adhesion and proliferation. Chondrogenic assessment based on scaffold extracts indicated that the incorporation of HA and its gradient distribution did not inhibit cartilage-related extracellular matrix synthesis, confirming the biosafety of the composite hydrogel system. Overall, this study presents a controllable and versatile fabrication strategy for constructing curved, compositionally graded cartilage scaffolds, providing a promising platform for the development of biomimetic cartilage tissue engineering constructs. Full article

This study presents a novel strategy for designing photocurable resins tailored for the additive manufacturing of smart thermoset materials. A quaternary formulation was developed by integrating bis(2-methacryloyl)oxyethyl disulfide (DADS) with an epoxy/thiol-ene system (ETES) composed of diglycidyl ether of bisphenol A (EP), pentaerythritol tetrakis(3-mercaptopropionate) (PTMP), and 4,4′-methylenebis(N,N-diallylaniline) (ACA4). This unique combination enables the simultaneous activation of four polymerization mechanisms: radical photopolymerization, thiol-ene coupling, thiol-Michael addition, and anionic ring-opening, within a single resin matrix. A key innovation lies in the exothermic nature of DADS photopolymerization, which initiates and sustains ETES curing at room temperature, enabling 3D printing without thermal assistance. This represents a significant advancement over conventional systems that require elevated temperatures or post-curing steps. The resulting hybrid poly(acrylate–co-ether–co-thioether) network exhibits enhanced mechanical integrity, shape memory behavior, and intrinsic self-healing capabilities. Dynamic Mechanical Analysis revealed a shape fixity and recovery of 93%, while self-healing tests demonstrated a 94% recovery of viscoelastic properties, as evidenced by near-overlapping storage modulus curves compared to a reference sample. This integrated approach broadens the design space for multifunctional photopolymers and establishes a versatile platform for advanced applications in soft robotics, biomedical devices, and sustainable manufacturing. Full article

This paper presents development and application of a Fiber Bragg Grating (FBG) array embedded in a 3D-printed insole for ground reaction force (GRF) estimation. In this case, a 3D-printed insole is fabricated from a scanned commercial insole in which a 5-FBGs array is integrated. The FBGs are characterized as a function of the applied transverse force, where a mean sensitivity of 0.11 ± 0.10 pm/N was obtained considering all FBGs. A portable FBG signal acquisition system was connected to the FBG array embedded in the insole and tested for the GRF analysis in a healthy volunteer. The gait tests results indicate stance and swing phases of 41.0 ± 6.5% and 59 ± 6.5%, respectively, which are within reference values of the literature. Furthermore, a 0.904 R² was found in the correlation analysis of the measured GRF response and the conventional M-shaped curve for the GRF in which all subdivisions of the stance phase were detected. Full article

Hybrid machining has considerable potential for industrial applications. The process allows the limitations of additive manufacturing to be reduced and high-precision components to be produced. This article discusses tests determining the impact of 3D printing parameters, machining parameters, and selected milling tools on achieving defined surface roughness values in parts made of PETG (polyethylene terephthalate glycol). Perpendicular-shaped samples were printed by fused deposition modelling (FDM) using variable layer heights of 0.1 mm and 0.2 mm and variable feed rates of 90, 100, 110, and 120 mm/s. Surface roughness values, topography, and Abbott–Firestone curves were determined using a Keyence VR-6000 profilometer. Straight grooves were machined in the test samples using a DMG MORI CMX 600V milling machine with a rotary burr, single-edge spiral burr cutter and spiral endmill. The microstructure was examined using a Motic inverted microscope. The surface roughness parameters of the grooves were investigated. The results confirmed that the use of hybrid machining (with a printed layer height L_h = 0.1 mm, V_feed = 120 mm/s, and a cutter–rotary burr) allows for lower surface roughness parameters, i.e., Ra = 1.54 μm. The relationships developed between printing, cutting, and milling tool parameters can be employed to predict the roughness parameters of filaments with similar characteristics. Full article

This paper performs orthotropic constitutive modeling for short carbon fiber-reinforced polyetheretherketone (CF-PEEK) composites fabricated using material extrusion 3D printing technology. A variety of specimens for tensile, compressive, and shear tests are 3D printed under different deposition path patterns. The related experimental results disclose the strong directional mechanical properties, including tensile/compressive modulus and strength. The Tsai–Wu failure criterion is also developed based on the experimental data. The tensile–compressive behavior models of different orthotropic materials were constructed by importing the experimental data into COMSOL, followed by a compression simulation of the S-shaped specimen. The experimental results of the S-shaped compression test were compared with the COMSOL-based simulation analysis, which validated the effectiveness of the Tsai–Wu failure prediction. The predicted failure timings, locations and load–displacement curves all show a good agreement with experimental observations. Furthermore, the Tsai–Wu failure index is incorporated as a stress constraint in structural topology optimization, showing the effect of significantly reduced stress concentration. These findings and data will be supportive for the design and optimization of 3D printed CF-PEEK composites. Full article

This paper presents the results of experimental and numerical analysis of fracture mechanics testing of ductile metallic materials using a non-standard procedure with PRNT (pipe ring notched tensile) ring-shaped specimens, introduced in previous publications through analysis of 3D-printed polymer rings. The main focus of this research is the determination of the values of the plastic geometry factor η_pl since the specimen is not a standard one. Toward this aim, the finite element software package Simulia Abaqus was applied to evaluate the J-integral (by using the domain integral method) and the F-CMOD curve so that the plastic geometry factor η_pl can be evaluated for different values of the ratio of crack length to specimen width (a₀/W = 0.45 ÷ 0.55). In this way, a procedure and the possibility of practical implementation on the thin-walled pipelines are established. Full article

The present study investigated the dynamic behavior of structures made of re-entrant unit cells subjected to cyclic compressive loading limited to the elastic range. The structures were assembled from printed polymer re-entrant cells in six combinations. Through the given compression cycles for three different amplitude values, strain-force relationships, which had the shape of a hysteresis loop, were obtained. Under compression, all unit cells of the structures deformed uniformly, though only for a certain amount of strain, whereas with larger changes, they underwent uncontrolled deformation. Experiments showed that structures composed of more than one unit cell exhibit different mechanical characteristics. It was observed that the width of the hysteresis loop depended on the degree of closing the structure and on the compression amplitude. The obtained hysteresis curves for different amplitudes also testify to the occurrence of the Mullins effect for these polymeric auxetic structures. Taking into account the maximum values of changes in dimensions for a given compression cycle, Poisson’s ratio values were determined, which were negative and below unity. The effect of strut thickness on the NPR was confirmed, decreasing its negative value along with the increasing thickness. Full article

The necessity of developing more realistic artificial food requires the aggregation of different biomaterials in an ordered and controlled manner. One of the most advanced methods for this is food printers reproducing additive manufacturing processes. This study presents a fully automatized 3D food printer leveraging collaborative Cartesian and multi-ink robotic systems to create complex food structures, with materials with different rheological settings using a screw conveyor configuration with controlled motion velocity. The developed food printer followed a formal mechatronic design strategy with fully functional instrumentation and automation systems. An adaptive controller was developed and implemented to regulate the coordinated operation of booth robotic devices, which are enforced by the G-code corresponding to the target food structure, leading to the necessary resolution. This device was tested with different commercial food inks to develop structures with complex shapes. The workability of the developed printer was confirmed by examining the food samples obtained using multiple materials, including creating different three-dimensional structures of a single complex food ink and creating simple structures made of different food inks with diverse structures that could yield a synthetic tissue that reproduces synthetic meat. Full article