Search Results (169)

Additive manufacturing (AM) enables the fabrication of complex, customisable components from metals, composites and polymers such as polylactic acid (PLA); however, the process commonly produces poor surface finishes and inherent defects. Centrifugal disc finishing (CDF) is an established mass finishing technique in conventional manufacturing but remains insufficiently characterised for additively manufactured polymers. This exploratory study investigates the influence of CDF on fused deposition modelling (FDM)-fabricated PLA components with varying geometrical features, focusing on three-dimensional surface parameters including average areal surface roughness, skewness and kurtosis. Samples were processed up to 720 min with analysis at predetermined intervals to capture transient and steady-state-like behaviour. Surface characterisation was conducted using non-contact optical interferometry to obtain quantitative roughness data and three-dimensional topographical maps, supported by digital optical microscopy and gravimetric analysis to quantify material removal rates. Analysis of the experimental data indicated apparent relationships between processing time, geometry and surface response. Results indicate that material removal behaviour and roughness evolution may be geometry-dependent. Flat and convex surfaces appeared to follow expected transient-like and steady-state-like behaviour, whereas restricted geometries and intricate features exhibited distinct responses with characteristic transition times. Surface roughness reductions ranged from 36% to 89% depending on geometry. These findings provide preliminary quantitative insight into geometry-specific mass finishing behaviour, supporting improved process understanding and informing future optimisation of post-processing strategies for additively manufactured polymer components. Full article

Fused filament fabrication (FFF) produces components with characteristic topographical features that influence their tribological behavior. Because conventional roughness parameters may not fully describe the localized surface degradation of reinforced FFF polymers, this study evaluates the wear-track evolution of FFF aramid fiber-reinforced Acrylonitrile Styrene Acrylate (ASA) composites using a comparative profilometric framework based on pre-wear and post-wear measurements. Specimens with different infill configurations underwent dry sliding Ball-on-Disc tribological testing, followed by profilometric wear-track analysis and optical microscopy inspection. The macroscopic wear response exhibited a non-monotonic dependence on infill configuration. Under the present experimental conditions, the 30% infill configuration showed the most favorable average wear response, with the lowest wear volume and specific wear rate, whereas the 90% infill configuration showed the highest material loss. To compare the surface modifications induced by sliding, three derived relative profilometric descriptors were evaluated: Surface Texture Alteration Index (STAI), Peak Deformation Index (PDI) and Material Ratio Preservation Index (MRPI). These descriptors were used as complementary comparative parameters rather than replacements for standardized roughness or Abbott–Firestone-based measurements. Statistical analysis showed a very strong association between maximum wear-track depth and calculated volumetric material loss, indicating that deeper wear-track profiles were consistently associated with higher material removal within the investigated dataset. Furthermore, correlation analysis suggested that the initial material ratio may be more closely associated with the subsequent wear response than the initial arithmetic mean roughness. This study indicates that combining wear volume, wear-track geometry, optical microscopy and relative profilometric descriptors provides a useful comparative approach for evaluating degradation in FFF Kevlar-reinforced ASA components under sliding conditions. Full article

Degenerative joint disease is a major cause of disability, and although glucocorticosteroids and hyaluronic acid are widely used to reduce inflammation and improve joint mobility, the development of effective delivery systems remains a challenge. This study describes injectable sodium hyaluronate (HA)-based hydrogels modified with synthetic polymers, including polyacrylic acid (PA), ammonium acryloyldimethyltaurate/VP copolymer (AX), a polyvinyl acetate–polyvinylpyrrolidone mixture (PVA–PVP), and polyethylene glycol 4000 (PEG), loaded with prednisolone disodium phosphate (PSP). The aim was to investigate molecular interactions between PSP and HA-based polymer networks and to determine how these interactions influence hydrogel structure, viscosity, and drug release. Viscosity was measured using a Brookfield rotational viscometer, while intermolecular interactions were analyzed by ATR–FTIR and DSC. Drug release was evaluated using a paddle-over-disc apparatus and quantified spectrophotometrically. Release kinetics were analyzed using zero-, first-, and second-order models as well as the Higuchi, Korsmeyer–Peppas, and Peppas–Sahlin equations. PSP incorporation affected the dynamic viscosity of all formulations, and excipient type also significantly influenced hydrogel viscosity. ATR–FTIR and DSC analyses indicated hydrogen bond formation between PSP and the macromolecules of HA, PA, AX, and PEG. The PA-containing formulation formed the most extensive polymer network structure and exhibited the highest viscosity. Drug release followed mainly first-order, Higuchi, and Korsmeyer–Peppas models, while the release exponent n (0.58 ± 0.01–0.60 ± 0.01) indicated anomalous transport. These findings provide molecular insight into drug–polymer interactions in HA-based hydrogels and highlight their potential as injectable systems for intra-articular delivery of PSP. Full article

Many advances in enhanced oil recovery (EOR) take advantage of the unique properties of nanomaterials to improve characterization of formation properties, achieve conformance control during flood operations, and extend the controlled release time of polymers. Magnetite nanoparticles (nMag) have been employed in these processes due to their low cost, low toxicity, and ability to be engineered to meet desired needs, especially with the application of a magnetic field. Similarly, silica dioxide (SiO₂) and aluminum oxide (Al₂O₃) nanoparticles have been evaluated for the delivery of scale and asphaltene inhibitors. However, the injection of nanoparticles into porous media comes with the risk of formation damage due to particle deposition, which can lead to increased injection pressures and reductions in permeability. The goal of this study was to develop a method to evaluate and assess nanoparticle formulations for their potential to cause formation damage. A screening apparatus was constructed to hold small sandstone discs (~2 mm) or cores (~2.5 cm) for rapid testing with minimal material use and the capability to be used with either aqueous brine solutions or non-polar solvents as the mobile phase. Image analysis of the disc and pressure measurements demonstrated increasing deposition of nMag and face-caking when the salinity was increased from 500 mg/L NaCl (8.56 mM) to API brine (2.0 M). Similarly, when the injected concentration of silica nanoparticles in 500 mg/L NaCl was increased from 1 to 10 wt%, the back pressure increased by 55 psi, and face-caking was observed. The screening test results were consistent with traditional core-flood tests and was able to be modified to accommodate organic liquid mobile phases. The screening test results closely matched nanoparticle transport and retention measured in sandstone cores, confirming the ability of the system to rapidly screen nanoparticle formulations for potential formation damage. Full article

External leakage from valve stem packings is a critical safety and reliability issue in high-pressure hydrogen systems. This work aims to quantify how packing geometry and polymer selection influence stem sealing in a PN650 needle valve (316L body and stem). Two geometries were compared: a conical V-ring (chevron style) stack and a flat three-disc stack. Two polymer material sets were assessed: Vespel^® polyimide (SP-1/SP-21) and a glass-filled PTFE sealing element combined with a virgin PEEK back-up ring. Four assemblies (one per geometry/material combination) were first screened by hydrostatic pressure hold testing up to 1500 bar and by helium mass spectrometer leak measurements under vacuum. All assemblies sustained the hydrostatic overpressure hold with negligible decay. Vacuum helium screening produced leak rates between 3.7 × 10⁻¹⁰ and 9.5 × 10⁻¹⁰ mbar·l·s⁻¹, with the conical V-ring geometry consistently outperforming the disc stack. A more demanding helium test at 700 bar with external vacuum yielded leak rates of 3.6–3.7 × 10⁻⁸ mbar·l·s⁻¹, for conical assemblies. Based on the screening results and practical industrial considerations, the PTFE/PEEK conical configuration was selected for endurance testing and completed 2500 open/close cycles in 650 bar hydrogen without gland readjustment. Post-cycling checks confirmed continued tightness, including a qualitative helium pressure hold result near 700 bar and 0 bubbles in 10 min in the seat tightness test. Microscopy/EDX revealed limited wear with minor metallic transfer. The proposed multi-stage workflow provides a pragmatic route for the early qualification of stem packings for high-pressure hydrogen valves. Full article

CAD/CAM polymer-based dental materials are increasingly used as metal-free alternatives for fixed and implant-supported restorations. High-performance polymers such as polyetheretherketone (PEEK), fiber-reinforced composites, and graphene-reinforced polymers have been introduced to improve material stability; however, evidence regarding the effects of thermal aging on their physicochemical and biological properties remains limited. In this study, PEEK, a fiber-reinforced composite (FRC), and a graphene-reinforced PMMA-based polymer (G-CAM) were evaluated. Twenty-seven disc-shaped specimens (10 × 2 mm; n = 9 per material) were fabricated and subjected to 10,000 thermal cycles between 5 and 55 °C. Color change (ΔE₀₀), surface roughness (Ra), and Vickers microhardness (VHN) were measured before and after aging. Chemical stability was assessed using FTIR and Raman spectroscopy, surface morphology by SEM analysis, and biological safety by cytotoxicity testing. Material-dependent differences were observed in color stability, surface roughness, and microhardness after thermal aging (p < 0.05). Microhardness decreased in the fiber-reinforced and graphene-reinforced materials, whereas PEEK showed no significant change. Spectroscopic analyses indicated preserved chemical structure, and all materials demonstrated acceptable cytocompatibility. Thermal aging influenced material behavior while chemical stability and biological safety were maintained, highlighting the importance of considering aging behavior during material selection for prosthetic restorations. Full article

This study investigated how fabrication method (milling versus 3D printing) affects the water sorption and solubility of PMMA dental materials, and how surface characteristics affect hydrolytic stability. Fifty-six PMMA samples were divided into three groups fabricated from CAD/CAM milled discs (Group A: I–III) and four groups from 3D-printed resin (Group B: IV–VII), each subjected to distinct postprocessing protocols. Water sorption (wsp) and solubility (wsl) were measured after immersion in distilled water at 37 °C for 24, 48, and 72 h, and 7 and 14 days. Surface topography and nanoroughness were assessed using atomic force microscopy (AFM). Statistical descriptive analyses were followed by correlation analyses. Milled PMMA demonstrated significantly lower water sorption and negative solubility (mass loss), indicating material dissolution. In contrast, 3D-printed PMMA showed higher water sorption and positive solubility (mass gain), reflecting water incorporation and polymer swelling. The kinetic profiles differed: milled PMMA displayed a monophasic absorption curve, while 3D-printed PMMA exhibited a biphasic pattern with accelerated water uptake after 72 h. AFM analysis revealed that 3D-printed surfaces had significantly greater nanoroughness than milled surfaces. Strong positive correlations were observed between surface roughness parameters (Sa, Sy) and water sorption capacity. The fabrication method was found to influence the hydrolytic stability of PMMA dental materials. Milled PMMA demonstrated superior stability, with lower water uptake, smoother surfaces, and lower leaching solubility. In contrast, 3D-printed PMMA exhibited increased surface roughness and water sorption, attributed to its layered microstructure and nanoporosity. Surface topography emerged as a strong predictor of wsl, related to hydrolytic degradation. For clinical applications, milled PMMA is recommended for long-term use requiring durability, whereas 3D-printed PMMA may be appropriate for short-term applications with optimised postprocessing. Full article

This study examined the association between biofilm growth and surface properties of 3D printed, milled, and conventional materials used for manufacturing fixed dental prostheses. Disc-shaped specimens were produced and finished from five 3D-printing resins (VarseoSmile Crown plus [VSC], NextDent C&B MFH [ND], VarseoSmile Temp [VST], Temp PRINT [TP], P Pro Crown & Bridge [P]), two polymer milling blocks (composite: TetricCAD [TC], PMMA: TelioCAD [TEL]), two conventional polymer materials (Tetric EvoCeram [TEC], Protemp 4 [PT]), and zirconia (ZR). Surface roughness (R_a), wettability, interfacial tension (IFT) and surface topography were examined. Three-day biofilms were grown on the specimens using A. naeslundii, S. gordonii, S. mutans, S. oralis, and S. sanguinis in a multi-species suspension. Biofilms were quantified by crystal violet staining and with a plating and culture method (CFU/mL). Linear regression analysis was computed to demonstrate associations between the surface properties and biofilm growth. The strength of this relationship was quantified by calculating Spearman’s ρ. TC exhibited the highest, and TP the lowest IFT. TEC showed the highest R_a, while TEL had the lowest, with significant differences detected particularly between milled and 3D-printed specimens. TP specimens exhibited the highest biofilm mass, while ZR surfaces retained the least. Bacterial viability within the biofilms remained similar across all tested materials. There was a strong negative correlation between total IFT and biofilm mass, and a moderate positive correlation between R_a and CFU/mL. Surface properties are shaped by material composition, microstructure, and manufacturing methods and play a crucial role in biofilm formation on dental restorations. Full article

Background and Objectives: Implant-associated complications, including foreign-body responses and infection risk, remain major concerns in reconstructive and aesthetic breast surgery. Antimicrobial polymer coatings have been proposed as potential preventive strategies, but early-stage development requires simple and ethically refined in vivo models. This pilot study aimed to (i) establish a practical workflow for applying PLGA–vancomycin coatings onto PTFE substrates used as experimental analogs for smooth silicone implants, and (ii) develop a small-animal implantation protocol for short-term evaluation of surgical feasibility and local tissue tolerability. Materials and Methods: PLGA microparticles and PLGA–vancomycin microparticles were prepared using a double-emulsion solvent-evaporation method and applied onto PTFE discs. Particle size and polydispersity were assessed based on dynamic light scattering (DLS), and surface charge was measured via zeta potential. A bilateral subcutaneous implantation model was used in four Wistar rats, each receiving a PTFE disc coated with PLGA-only on one side and a disc coated with PLGA–vancomycin on the other. Animals were monitored for postoperative recovery, wound appearance, and general condition. After four weeks, implants and surrounding tissues were harvested for macroscopic and preliminary histological evaluation. Results: Both PLGA-only and PLGA–vancomycin microparticles showed submicron mean hydrodynamic diameters and moderately polydisperse distributions typical for double-emulsion formulations. All animals recovered normally, maintained stable body weight, and exhibited no macroscopic signs of adverse reactions. Preliminary histology showed early fibrous capsule formation with mild inflammatory infiltrate around both types of coated implants, without qualitative differences observed in this pilot setting. Conclusions: This preliminary study demonstrates the feasibility of applying PLGA-only and PLGA–vancomycin coatings onto PTFE implant analogs and establishes a reproducible, minimal-use rat model for short-term evaluation of local tissue tolerability. The protocol provides a practical foundation for future work on coating stability, drug-release kinetics, antibacterial activity, and long-term tissue responses on medical-grade silicone substrates. Full article

Organic field-effect transistors (OFETs) require reliable micro- and nanoscale patterning of semiconducting layers, yet conjugated polymers have long been considered incompatible with photolithography due to dissolution and chemical damage from photoresist solvents. Here, we present a photolithography-compatible strategy based on doping-induced solubility conversion (DISC), demonstrated using poly[2,5-bis(3-tetradecylthiophen-2-yl)thieno[3,2-b]thiophene] (PBTTT). AuCl₃ doping reversibly modulates the benzoid/quinoid resonance balance, lamellar stacking, and π–π interactions, suppressing solubility during lithographic exposure, while dedoping restores the intrinsic electronic properties. Using this approach, micropatterns with linewidths as small as 2 µm were fabricated in diverse geometries—including line arrays, concentric rings, dot arrays, and curved channels—with high fidelity; quantitative analysis of dot arrays yielded mean absolute errors of 48–66 nm and coefficients of variation of 2.0–3.9%, confirming resolution and reproducibility across large areas. Importantly, OFETs based on patterned PBTTT exhibited charge-carrier mobility, threshold voltage, and on/off ratios comparable to spin-coated devices, despite undergoing multiple photolithography steps, indicating preservation of transport characteristics. Furthermore, the same DISC-assisted lithography was successfully applied to other representative p-type conjugated polymers, including P3HT and PDPP-4T, confirming the universality of the method. This scalable strategy thus combines the precision of established lithography with the functional advantages of organic semiconductors, providing a robust platform for high-density organic electronic integration in flexible circuits, biointerfaces, and active-matrix systems. Full article

This study quantifies how pressurized water-immersion aging degrades the tribological response of cross-ply E-glass/polyester laminates by coupling dual-mode testing with surface metrology and factorial ANOVA. Eleven-ply [0/90]s plates were aged at 10 bar for 0, 7, 14, and 21 days, gaining 10% mass (72.2 to 79.4 g), then tested under 20 N in ball-on-disc (50–100 mm s⁻¹; 100–200 m) and reciprocating modes (1–2 Hz; 10–20 m). In ball-on-disc tests, steady-state COF rose from 0.40 to 0.47 (unaged) to 0.49 to 0.52 (14–21 days), and the low-friction run-in largely vanished with aging. Wear scar width and depth increased from 1.38 to 1.90 mm and 75 to 117 µm, respectively. Reciprocating tests showed a non-monotonic trend: moderate aging lowered COF to 0.50, whereas 21 days produced the harshest response (up to 0.78) and the widest/deepest scars (1.15 to 1.95 mm; 40 to 110 µm). ANOVA revealed that, in ball-on-disc tests, the COF was governed by sliding distance (28.70%) and speed (24.64%), with a strong Days × Speed interaction (31.66%); track-depth variance was dominated by distance (42.16%) and aging (32.16%). For the COF under reciprocating tests, aging was the leading main effect (21.21%), with large Days × Frequency (20.36%) and Days × Track (20.03%) interactions. Uniquely, this study isolates the effect of controlled hydrostatic aging (10 bar) and compares two sliding kinematics under identical loads, establishing quantitative thresholds (14 and 21 days) where interfacial debonding and third-body abrasion accelerate. Full article

Hydrogel-based biosensors are commonly used in diagnostic applications. However, their performance remains constrained by slow analyte diffusion within polymer matrices, particularly when larger biomolecules are involved. Concave hydrogel geometries present a promising solution to enhance diffusion rates through increased surface area. However, the interfacial dynamics governing their formation must be studied. In this research, we investigated the interfacial dynamics that influence the formation of concave hydrogel discs fabricated by a simple pipetting method. We characterized the fluid interactions occurring during droplet deposition of alginate and CaCl₂ solutions. A three-phase flow model incorporating confocal microscopy validation was employed to simulate time-dependent interfacial behaviors. Concave hydrogel discs fabricated with alginate-first deposition exhibited 83% larger surface area compared to hemispherical counterparts at a CaCl₂: alginate volume ratio of one. Increasing the volume ratio further enhanced both surface area and diameter, though this highlighted limitations for microscopy-based detection. According to our results, reaction speed in alginate concave hydrogel discs can be controlled by varying the volume of CaCl₂ solution while keeping the volume of alginate solution constant, which changes the surface area while maintaining constant hydrogel volume. Full article

Background: The aesthetic performance of single-shade polymer-based restorative materials (SPRs) can be compromised by extrinsic stains. Understanding the effects of novel whitening interventions on SPRs is crucial. Objective: This in vitro study aimed to evaluate the effects of different whitening interventions, including a novel purple tooth serum and charcoal-based whitening toothpaste with and without in-office bleaching, on the color of a new coffee-stained SPR. Materials and Methods: Seventy disc-shaped SPR specimens were prepared, stained, and then divided into seven groups (n = 10). Three groups were subjected directly to 2500 cycles of brushing simulation with regular toothpaste (control), charcoal toothpaste, or purple tooth serum. The rest were divided into bleaching groups, and the four groups underwent a simulation of bleaching and then brushing with the three products. The color parameters were recorded at the stained baseline, after brushing, after bleaching, and after post-bleaching brushing. The color change (ΔE00) was calculated, and the data were analyzed statistically using the Kruskal–Wallis test and Dunn–Bonferroni pairwise comparisons (p < 0.05). Results: In-office bleaching without brushing had a statistically significantly higher ΔE00 value than all other groups (p < 0.001). Post hoc tests indicated that the ΔE00 values of the brushed specimens were not significantly different from each other when assessed with and without bleaching (p > 0.05). When using the charcoal toothpaste, the post-bleaching brushed specimens had a noticeable color change above the PT. Conclusions: Bleaching improved the stained SPR color initially, but other treatments may offer longer-lasting aesthetics. The charcoal toothpaste showed promising results when combined with bleaching. The purple serum showed limited effectiveness. Full article

This study investigates the interplay between infill structure and surface texture in Fused Deposition Modeling (FDM)-printed polymer specimens and their combined influence on tribological and mechanical performance. Unlike previous works that focus on single-variable analysis, this work offers a comparative evaluation of Shore D hardness and coefficient of friction (COF) for PLA and Iglidur materials, incorporating diverse infill patterns. The results reveal that specific combinations (e.g., grid infill with 90% density) optimize hardness and minimize friction, offering practical insights for design optimization in functional parts. Our aim is to provide design insights for enhanced wear resistance and hardness through tailored structural configurations. Carbon Fiber-reinforced PLA (PLA CF), aramid fiber-reinforced Acrylonitrile Styrene Acrylate (Kevlar), and Iglidur I180-BL tribofilament. Disc specimens were fabricated with gyroid infill densities ranging from 10% to 100%. Experimental methodologies included Ball-on-Disc tests conducted under dry sliding conditions (5 N normal load, 150 mm/s sliding speed) to assess friction and wear characteristics. These tribological evaluations were complemented by profilometric and microscopic analyses and Shore D hardness testing. The results show that Iglidur I180-BL achieved the lowest friction coefficients (0.141–0.190) and negligible wear, while PLA specimens with 90% infill demonstrated a polishing-type wear with minimal material loss and a friction coefficient (COF) of ~0.108. In contrast, PLA CF and Kevlar exhibited higher wear depths (up to 154 µm for Kevlar) and abrasive mechanisms due to fiber detachment. Shore hardness values increased with infill density, with PLA reaching a maximum of 82.7 Shore D. These findings highlight the critical interplay between infill architecture and surface patterning and offer actionable guidelines for the functional design of durable FDM components in load-bearing or sliding applications. Full article

In this study, polymer matrix composites based on high-density polyethylene (HDPE) and recycled HDPE (HDPEr) were reinforced with zinc oxide nanoparticles (ZnO NPs). Four formulations (M1-M4) with HDPE/HDPEr/ZnO NP mass ratios of 50/50/0, 48/47/5, 45/45/10, and 43/42/15 were produced via melt injection molding. Disc-shaped samples (Ø30 ± 0.1 mm × 2 ± 0.1 mm) were evaluated in unaged and aged states (840 h at 100% humidity and 100 °C) using scanning electron microscopy, X-ray diffraction, ultraviolet–visible and Fourier-transform infrared spectroscopy, water absorption, thermal resistance, and mechanical and dielectric testing. Among all composites, M2 showed the best performance, with the highest aging resistance (estimated lifetime of 3891 h in humidity and 2361 h in heat). It also exhibited superior mechanical properties, with the highest indentation hardness, Vickers hardness, and elastic modulus before (0.042 GPa, 3.846 HV, and 0.732 GPa) and after aging under humidity (0.042 GPa, 3.932 HV, 0.706 GPa) and elevated temperature (0.085 GPa, 7.818 HV, 1.871 GPa). Although ZnO NPs slightly reduced electrical resistivity, M2 showed the most stable dielectric properties. In its unaged state, M2 had 22%, 30%, and 3% lower surface resistivity, volume resistivity, and dielectric strength, respectively, than M1 polymer. M2 was identified as the optimal formulation, combining mechanical strength, dielectric stability, and resistance to moisture and heat. Full article