Search Results (81)

The integration of additive manufacturing technology and biomimetic design provides new possibilities for functional and aesthetic innovation in automotive interiors. This study explores a roof handrail design method based on a spider web biomimetic structure from the perspectives of object character and design freedom. By transforming the spider web morphology of nature into a manufacturable parametric model, the organic unity of structural performance and visual aesthetics has been achieved. The simulation results show that the spider web biomimetic structure handrail distributed along the z-axis not only meets the mechanical performance (maximum stress of 189.11 MPa under 1500 N load) but also theoretically reduces weight by 32.03% compared to traditional designs. Material testing shows that the spider web biomimetic structure handrail made of PA6-CF material through fused deposition molding not only meets safety requirements but also has a better user experience. This study achieved organic forms that are difficult to process with traditional techniques through 3D printing technology, providing a new paradigm of “form following ecology” for automotive interior design and expanding the possibilities of functional components in user experience and spatial narrative. 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

Conventional formwork systems are limited in their ability to efficiently realize complex and free-form concrete geometries, while additive manufacturing (AM)-based formwork faces constraints in casting-stage structural stability and cost-effectiveness, particularly at construction scale. To address these limitations, a hybrid formwork system integrating a structural steel frame with 3D-printed modules is proposed, in which the steel frame resists casting-induced lateral pressure while the printed components define complex mold geometries. The system was fabricated and validated through a full-scale case study structure measuring 3.0 m × 1.7 m × 2.2 m, produced using a large-scale fused deposition modeling (FDM) process with carbon-fiber-reinforced ABS (ABS-CF20). Geometric accuracy was evaluated by comparing design dimensions with as-built measurements across planar, edge, curved, and inclined regions. Construction efficiency and cost performance were assessed through process-based and cost-based comparisons with conventional steel formwork and fully 3D-printed formwork alternatives. The constructed structure reproduced the intended geometry with an average deviation of approximately 3.2 mm and a maximum deviation within ±4 mm, and no notable formwork deformation or damage was observed during concrete casting. Relative to conventional steel formwork, the hybrid system reduced total fabrication duration by about 50% and fabrication cost by about 60% based on a normalized cost index, while also outperforming fully 3D-printed formwork in cost efficiency by about 45%. The modular configuration and bolted connection system further improved transportability, on-site assembly efficiency, and component reusability. These findings demonstrate that the proposed hybrid formwork system provides a practical and resource-efficient pathway for fabricating complex concrete structures, supporting the broader adoption of digital fabrication in sustainable construction practice. Full article

Percutaneous tracheotomy represents a critical airway procedure, yet training opportunities in pediatric patients remain limited due to the low incidence and high risk associated with the procedure. Simulation-based training plays a key role in enabling physicians to develop procedural skills in a safe environment. This study presents the design, fabrication, and validation of a high-fidelity physical simulator for pediatric percutaneous tracheotomy using the Frova screw technique. The simulator reproduces the anatomy of an eight-year-old patient in a hyperextended neck position, allowing rigid bronchoscope insertion, and includes relevant anatomical landmarks. The presence of a blood pocket enhances procedural realism. The modular design, with a reusable base and disposable cartridge, enables rapid reset between sessions while minimizing maintenance costs. Soft tissues were reproduced through silicone molding, while rigid components were fabricated using fused deposition modeling 3D printing. Validation was performed by 39 physicians using a structured five-point Likert scale questionnaire. The simulator achieved a mean score of 4.2/5, with item scores ranging from 3.6 to 4.7, indicating a high level of perceived realism, procedural fidelity, and educational value, as well as highlighting potential areas of improvement. These findings suggest that the proposed simulator is a useful tool for simulation-based education, with the potential to improve operator confidence and patient safety in complex airway emergencies. Full article

Background: Achieving facial harmony in patients with micrognathia requires precise chin augmentation. While conventional ready-made implants often fail to conform to unique mandibular surfaces, expensive patient-specific options like PEEK or Titanium lack intraoperative adjustability. We introduce an innovative, cost-effective workflow utilizing 3D-printed templates to fabricate customized Polymethyl Methacrylate (PMMA) implants, emphasizing their clinical feasibility and intraoperative versatility. Methods: We retrospectively analyzed 20 patients with mild-to-moderate micrognathia (<6 mm advancement) who underwent genioplasty between March 2021 and June 2022. Patient-specific templates were produced via Fused Deposition Modeling (FDM) using low-shrinkage Acrylonitrile Butadiene Styrene (ABS) filament. During surgery, final PMMA implants were molded using these sterilized templates. Accuracy was evaluated by comparing mental advancement across preoperative, virtual simulation, and 6-month postoperative stages using Vectra 3D scanning. Results: Quantitative analysis revealed high fidelity between virtual planning and clinical outcomes. The mean discrepancy in horizontal advancement was only 1.02 mm (Planned: 5.04 mm vs. Actual: 4.02 mm). Statistical analysis showed a strong positive correlation (r = 0.928, p = 0.001). Subjective patient satisfaction was high, with 90% reporting “exceptional” or “very improved” results on the Global Aesthetic Improvement Scale (GAIS). Two cases of transient numbness resolved spontaneously within two months. Conclusions: This workflow combines FDM-based template fabrication with intraoperative PMMA molding, enabling real-time adjustment of implant geometry. The results demonstrate a high level of agreement between virtual planning and postoperative outcomes, supporting the clinical reliability of this approach. It may serve as a practical alternative to conventional CAD/CAM methods, particularly in cases requiring both precision and intraoperative flexibility. Full article

The widespread deployment of service robots in domestic and professional environments demands structural solutions that simultaneously achieve high stiffness, low mass, and intrinsic safety. Traditional metallic structural designs face a fundamental physical conflict: achieving high stiffness typically results in excessive mass, which compromises operational safety and battery life. To solve this, this paper presents a critical review of an integrated lightweighting strategy combining material selection, structural design, and additive manufacturing for Carbon-Fiber-Reinforced Polymer (CFRP) service robot structures. Three critical findings are presented. First, specific stiffness is established as the governing criterion for material selection, providing a unified basis to resolve the stiffness–mass conflict. Second, among current 3D printing techniques, Fused Deposition Modeling (FDM) with continuous-fiber reinforcement overcomes the geometric constraints of traditional molding, enabling the fabrication of complex, customized structures. Third, to realize the full potential of 3D-printed CFRP, we highlight the importance of integrating material properties (anisotropy), structural design (topology optimization), and manufacturing processes (path planning) into a concurrent framework. This integrated approach is validated through a collaborative robotic-arm case study, achieving a 30% reduction in structural mass. Full article

Fused granular fabrication (FGF) offers high deposition efficiency and low material cost for large-scale mold production, but commonly yields parts with surface defects and dimensional deviations. This study develops a six-axis robotic post-processing workstation that integrates multi-DOF toolpath planning and real-time communication to flexibly machine FGF components with complex geometries. Using short-fiber-reinforced polypropylene (PP-GF), robotic milling experiments were performed, and spindle speed, feed rate, and cutting depth were systematically optimized to enhance surface quality and dimensional accuracy. The NSGA-III algorithm optimizes parameters, thereby increasing machining efficiency by 4.9% and reducing surface roughness by 12.35%. Results show that the proposed platform effectively improves the machining performance of FGF-printed parts, demonstrating its feasibility for high-precision post-processing. The work provides a practical technical route for the hybrid additive–subtractive manufacturing of large 3D-printed structures. Full article

Three-dimensional (3D) printing offers new opportunities in surgical planning and medical education, yet high costs and technological complexity often limit its widespread use, especially in low-resource settings. This study presents a personalized, cost-effective, and anatomically accurate liver model designed using open-source tools and affordable 3D-printing techniques. Segmentation of hepatic CT images was performed in 3D Slicer using a region-growing method, and the resulting models were optimized and exported as STL files. The external mold was printed with Fused Deposition Modeling (FDM) using PLA+, while internal structures such as vessels and tumors were fabricated via Liquid Crystal Display (LCD) printing using PLA Pro resin. The final assembly was cast in food-grade gelatin to mimic liver tissue texture. The complete model was produced for under USD 50, with an average total production time of under 128 h. An exploratory pedagogical evaluation with five medical trainees yielded high Likert scores for anatomical understanding (4.6), spatial awareness (4.4), planning confidence (4.2), and realism (4.4). This model demonstrated utility in preoperative discussions and training simulations. The proposed workflow enables the fabrication of low-cost, realistic hepatic phantoms suitable for education and surgical rehearsal, promoting the integration of 3D printing into everyday clinical practice. Full article

Three-dimensional (3D) printing has become a promising alternative to conventional methods in plastic part production, particularly for customized or low-volume applications such as toys. This study compares toy components produced by Fused Deposition Modeling (FDM) using polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) filaments and those produced by traditional injection molding using ABS pellets. Unlike in many previous studies based on standardized test samples, a real toy part was evaluated in terms of compressive strength, dimensional accuracy, surface quality, and cost. Experimental results revealed that ABS parts produced by injection molding exhibited the highest compressive strength (3.93 kN), followed by PLA-FDM (2.97 kN) and ABS-FDM (0.95 kN). Similarly, injection-molded parts showed superior surface smoothness and dimensional accuracy. Cost analysis indicated that injection molding is economically viable only when production exceeds 735 pieces, while FDM becomes more attractive for smaller batches due to its low initial cost. A multi-criteria decision-making analysis using the TOPSIS method was conducted to integrate technical and economic factors. Results showed that injection molding is preferable for mass production, whereas PLA-FDM is more suitable for low-quantity, cost-sensitive scenarios. Full article

In this paper, we are looking for the answer to the following question: what geometric deviations do polymer gears made by 3D printing have from the theoretical geometry? From a practical point of view, the question is whether the currently installed injection-molded gear can be replaced by a 3D-printed gear. Thus, the measurements are also carried out on the sample gear and the comparison is made with this data as well. Knowing the data of the existing gear wheel, the CAD model was created, and based on this, samples of the gear were printed using various 3D printing machines. The printed gears were then subjected to geometrical analysis. During the inspection, we performed the measurement of the chordal thickness of the gear wheel using a gear tool caliper, instead of pin measurement and span measurement using a special micrometer, and 3D scanning and analysis. A surface roughness measurement was carried out as well. By conducting measurements on the injection-molded and 3D-printed samples, this research seeks to evaluate the reliability and limitations of the 3D-printed gears, providing insights into their industrial use. This study aims to determine whether 3D printing technologies can produce gears with sufficient accuracy and surface quality for practical applications. Based on the conducted analysis, general conclusions were drawn regarding the potential applicability of the 3D-printed gears. The experimental results indicate notable differences in dimensional accuracy between gears manufactured using Fused Deposition Modeling (FDM) and Selective Laser Sintering (SLS). In terms of chordal thickness measurements, FDM gears exhibited a mean relative error of 1.96 mm, whereas SLS gears showed a significantly higher average deviation of 5.64 mm. For the pin measurement, the relative error averaged 0.193 mm in the case of FDM gears, compared to 0.616 mm for SLS gears. Similarly, the span over four teeth measurements resulted in an average deviation of 0.153 mm for FDM gears, while SLS gears demonstrated a markedly higher mean error of 0.773 mm. With regard to surface roughness, it can be concluded that SLS-manufactured gears exhibit superior performance compared to FDM gears, with an average Ra value of 2.65 µm versus 9.28 µm, although their surface quality remains inferior to that of the injection-molded gear. In light of the higher relative errors observed in SLS gears compared to FDM gears, the dimensions of the theoretical model should be refined to improve the manufacturing accuracy of SLS-produced gears. Full article

This paper review deals with frequent technologies of the production of materials based on Wood Plastic Composite, their brief definition, and description of components. The choice of processing technology depends on the polymer applied and the shape required of the part or the component. In the case of thermoplastic matrices, the dominant are extrusion and injection molding. In the case of thermosets application, the following technologies can be used: Resin Transfer Molding and Sheet Molding Compound. Currently, the research is also widely focused on composites with a matrix made of biodegradable thermoplastics—polylactide, which also brings to the forefront 3D printing technology of Fused Deposition Modeling. Each of these technologies is—to a certain extent—limited and impacts on the final characteristics of the composite material and its use. Full article

Microfluidic technology is an emerging interdisciplinary field that uses micropipes to handle or manipulate tiny fluids in chemistry, fluid physics, and biomedical engineering. As one of the rapid prototyping methods, the three-dimensional (3D) printing technique, which is rapid and cost-effective and has integrated molding characteristics, has become an important manufacturing technology for microfluidic chips. Polymethyl-methacrylate (PMMA), as an exceptional thermoplastic material, has found widespread application in the field of microfluidics. This paper presents a comprehensive process study on the fabrication of fused deposition modeling (FDM) 3D-printed PMMA microfluidic chips (chips), encompassing finite element numerical analysis studies, orthogonal process parameter optimization experiments, and the application of 3D-printed integrated microfluidic reactors in the reaction between copper ions and ammonium hydroxide. In this work, a thermal stress finite element model shows that the printing platform temperature was a significant printing parameter to prevent warping and delamination in the 3D printing process. A single printing molding technique is employed to fabricate microfluidic chips with square cross-sectional dimensions reduced to 200 μm, and the microchannels exhibited no clogging or leakage. The orthogonal experimental method of 3D-printed PMMA microchannels was carried out, and the optimized printing parameter resulted in a reduction in the microchannel profile to Ra 1.077 μm. Finally, a set of chemical reaction experiments of copper ions and ammonium hydroxide are performed in a 3D-printed microreactor. Furthermore, a color data graph of copper hydroxide is obtained. This study provides a cheap and high-quality research method for future research in water quality detection and chemical engineering. Full article

The paper presents a simple and cost-effective way of enhancing the thermal conductivity of the paraffin/graphite phase change material (PCM) composite spheres manufactured by using a low-cost and eco-friendly method. The composite materials were made of an admixture of 5–20% vol. graphite powder. The manufacturing process of macro-encapsulated PCM consists of creating digital models, mold printing, and PCM injections. The experimental data shows that composite materials have an increased thermal conductivity, from 3 to 11 times compared to paraffin, and are effective in cooling application of electronic components where they lowered the maximum temperature up to 30 °C. For low-volume PCM sphere fabrication, it was proposed the injection molding in the 3D printed mold; the results show that fused deposition modeling (FDM) is efficient in saving energy up to 30% compared to machining. The carbon emissions generated during the fabrication technology were found to be strongly dependent on printing process parameters and the energy mix used to produce the electrical energy used. Full article

Orthopedic soft tissue injuries, such as those to the fibrocartilaginous meniscus in the knee, present a significant clinical challenge, impacting millions globally and often requiring surgical interventions that fail to fully restore mechanical function. Current bioengineered meniscal replacement options that incorporate synthetic and/or natural scaffolds have limitations in biomechanical performance and biological integration. This study introduces a novel scaffold fabrication approach, termed Hybrid Hydrogels Augmented via Additive Network Integration (HANI) with great potential for meniscal tissue engineering applications. HANI scaffolds combine cross-linked gelatin-based hydrogels with polycaprolactone (PCL) additive networks, created via Fused Deposition Modeling (FDM), to enhance mechanical strength and replicate the anisotropic properties of the meniscus. Custom Stereolithography (SLA)-printed molds ensure precise dimensional control and seamless incorporation of PCL networks within the hydrogel matrix. The mechanical evaluation of HANI scaffolds showed improvements in compressive stiffness, stress relaxation behavior, and load-bearing capacity, especially with circumferential and 3D PCL reinforcements, when compared to hydrogel scaffolds without additive networks. These findings highlight HANI’s potential as a cost-effective, scalable, and tunable scaffold fabrication approach for meniscal tissue engineering applications. Full article

Thermoplastic polycarbonate polyurethane (PCU) has been applied in numerous biomedical applications owing to its superior properties. The objective of this study is to obtain the comprehensive performance of PCU materials with different hardness processed through various molding methods. The performance will be compared with that of natural intervertebral discs to assess their degree of match, with the expectation of further enhancing the application of PCU in the field of elastic intervertebral disc products. PCU materials with four different hardness grades, namely 75A, 85A, 95A, and 55D, were prepared through injection molding (IM), compression molding (CM), and fused deposition modeling in three-dimensional printing (3D). Material property analysis and mechanical performance characterization were conducted on the PCU materials. The PCU materials processed through the three different molding methods exhibited similar results in terms of hardness, scanning electron microscopy (SEM) images, X-ray energy-dispersive spectroscopy (EDS) spectra, and attenuated total reflection Fourier-transform infrared (ATR-FTIR) spectra, indicating that the materials did not degrade or introduce impurities during the molding process and the molding methods used in this study were acceptable. Differences were observed in the tensile and compressive properties of PCU materials. The mechanical properties of 85A- and 95A-hardness materials processed by CM and 3D molding were relatively close to those of natural intervertebral discs. In terms of water contact angle, under the same hardness condition, the materials processed by CM molding exhibited the largest water contact angle, while those processed by IM and 3D molding were similar. The PCU materials with 85A and 95A hardness processed through IM, CM, and 3D exhibited properties that were close to the performance requirements of natural intervertebral discs. There is a high potential for their application in intervertebral disc products to enhance product performance, replace diseased natural discs, and promote the development of cervical total disc replacement (TDR) surgery. Full article