Search Results (61)

Background: In children with cerebral palsy, bony acetabular deficiencies are common and may be associated with progressive hip subluxation, abnormal joint loading, and ultimately hip dislocation. Hip reconstruction surgery is typically performed to prevent dislocation, and this includes acetabular reshaping using acetabuloplasty. The location of acetabular deficiency may vary among individuals; however, only radiographs are used for planning and intraoperative correction in many centers. Precise reconstruction and preop planning are necessary for the accurate correction of acetabular coverage. This study compares conventional hip reconstruction with a 3D-guided technique using individual preop 3D planning and 3D-printed guides during surgery to determine which method allows for a more accurate correction. We hypothesize that the patient-specific 3D planning leads to more precise anatomical correction of acetabular coverage compared to conventional freehand osteotomy. Methods: This study was registered in the German Clinical Trial Register (DRKS-ID: DRKS00031356) on 14 July 2023. In a randomized controlled trial, various imaging-based parameters were used to assess the bony anatomy preoperatively and postoperatively. Preoperative and 6-week postoperative computed tomography (CT) scans are part of routine clinical care. Additionally, an immediate postoperative CT scan was performed. One hip was operated on using individualized 3D preoperative planning, while the other hip was corrected using a conventional surgical approach. A standardized subtrochanteric osteotomy was performed for the varisation, derotation, and shortening of the proximal femur. This osteotomy was followed by acetabuloplasty under fluoroscopic control. For the 3D-planned operation, patient-specific cutting and repositioning guides were produced based on preoperative CT imaging. Patients with bilateral cerebral palsy (GMFCS levels I–V), aged 4–18 years, with an open triradiate growth plate and a migration index ≥ 40% in at least one hip were included. In a preliminary retrospective part, this project reproduces the existing three-dimensional acetabular index (3-DAI) and compares it with established radiographic methods to determine the utility and reliability of a reconstructed 3D CT measurement technique. A further component of the retrospective part is the creation of an age-adjusted database of typically developed hips and the development of a 3D head coverage index (3D-HCI) as a new 3D parameter to express acetabular coverage; therefore, it will be used as a secondary parameter and correlated to the 3DAI in the prospective part. Conclusions: Improved precision may have meaningful clinical implications for long-term joint congruency, load distribution, pain, and mobility outcomes. Full article

Impellers are critical components in industrial applications, requiring smooth surfaces and precise dimensions. Traditional investment casting methods are often time-consuming and costly. Fused filament fabrication (FFF), an additive manufacturing (AM) technology, offers a faster, more cost-effective alternative. FFF produces 3D-printed sacrificial patterns directly from a CAD file, making it ideal for low-volume and complex patterns. Unlike wax patterns, which can shrink or distort, 3D-printed patterns offer precise tolerances and allow for thin-walled geometries. FFF also eliminates the need for tooling, reducing capital investment. However, achieving the desired surface finish and accuracy remains a challenge. In this study, a semi-open, single-shrouded centrifugal pump impeller was fabricated using FFF with acrylonitrile butadiene styrene (ABS). A Taguchi L9 (3³) design of experiments was employed to investigate the influence of layer thickness (0.08–0.24 mm), extrusion temperature (260–280 °C), and infill density (30–70%) on dimensional accuracy and surface roughness. Dimensional deviations were evaluated for critical features, including outer diameter (OD), inner diameter (ID), blade thickness (BT), shroud thickness (ST), and blade height (BH). Results show that small and thin features (BT, ST, BH) exhibited deviations with standard deviations below 0.08 mm, whereas OD was the most affected feature with a maximum standard deviation of 0.362 mm due to dominant shrinkage effects. The optimal parameter combination for minimum dimensional deviation was identified as 0.08 mm layer thickness, 280 °C extrusion temperature, and 70% infill density. Surface roughness analysis revealed that layer thickness was the most significant factor, with Ra values ranging from 4 to 7 µm, which falls within acceptable limits for investment casting. Surfaces parallel to the XY plane demonstrated superior surface quality compared with XZ/YZ planes, highlighting the feasibility of FFF-printed ABS patterns for investment casting of complex impellers. Full article

Objectives: The aim of this in vitro study was to evaluate the accuracy of intraoral impressions obtained using the Trios 3Shape^® (3Shape Trios, Copenaghen, Denmark) and Carestream CS 3600™ (Carestream Dental, Stuttgart, Germany) scanners, compared with traditional polyvinyl siloxane (PVS) impressions. A laboratory scanner served as the gold standard. Materials and Methods: The study was based on 3D-printed master models derived from partially edentulous clinical cases previously treated at our department (2017–2022). All cases required at least two implants. Data analysis was performed using one-way ANOVA and two-sample Z-tests (α = 0.05) to compare mean deviations and variability. Results: All techniques demonstrated high accuracy, with deviations from the reference point below 30 μm. The digital intraoral scanners (Trios 3Shape^® and Carestream CS 3600^®) showed superior accuracy compared with PVS analog impressions, with no statistically significant difference between the two IOS systems. Conclusions: Within the limitations of this in vitro study, both IOS systems and PVS analog impressions achieved clinically acceptable accuracy. Digital systems exhibited improved performance in terms of mean deviation and consistency. The higher accuracy and consistency of digital impressions may translate into improved clinical efficiency and prosthetic fit in implant rehabilitations. From a clinical perspective, these in vitro findings suggest that digital impressions may enhance prosthetic fit and workflow efficiency, though further in vivo validation is required. Clinical significance: This study supports the reliability of intraoral scanning compared with conventional impressions in implant-supported rehabilitations. By demonstrating high intrinsic accuracy, these findings contribute to optimizing digital workflows in implant dentistry and reinforce the potential of intraoral scanning in static computer-guided, flapless implant surgery. Trial registration: Ethical approval and trial registration were not applicable to the present in vitro investigation, as no patients were directly involved in the experimental phase. The digital data used to generate the laboratory master models originated from a separate clinical study conducted at ASST Santi Paolo e Carlo, Milan (Ethics Committee approval no. 1361, 12 July 2017; ClinicalTrials.gov registration, Unique Protocol ID 1361). Full article

We present a flexible pH sensor which leverages the unique properties of reduced graphene oxide/polyaniline (rGO/PANI) composite films through an efficient and scalable hybrid microfabrication approach, wherein the rGO/PANI films are conformally coated on flexible polyethylene terephthalate (PET) substrates via dip-coating and thereafter lithographically patterned into precise arrays of interdigitated electrodes (IDEs), serving both as the pH-active medium and the electrical interface. Upon dip-coating, a thermal reduction process is performed to yield uniform rGO/PANI composite layers on PET substrates, where the PANI content is adjusted to 20% to optimize conductivity and protonation-driven response. Composition optimization is first performed using inkjet-printed silver (Ag) contacts and a conductometric readout mechanism is employed to explore pH-dependent behavior. Subsequently, IDE arrays are defined in the rGO/PANI using photolithography and oxygen-plasma etching, demonstrating clean pattern transfer and dimensional control on flexible substrates. Eliminating separate contact metals in the final design simplifies the stack and reduces cost. A set of IDE geometries is evaluated through I–V measurements in buffers of different pH values, revealing a consistent, monotonic change in electrical characteristics with pH and geometry-tunable response. The present study demonstrated that the most precise pH measurement was achieved with an 80:20 rGO/PANI composition within the pH 2–10 range. These results establish rGO/PANI IDEs as a scalable route to low-cost, miniaturized, and mechanically compliant pH sensors for field and in-line monitoring applications. Full article

The progressive aging of the population requires reliable, non-invasive, and real-time tools to monitor hydration, prevent dehydration-related complications, and promote active aging in elderly patients. Wearable sensors based on interdigitated electrodes (IDEs) and on Electrochemical Impedance Spectroscopy (EIS) represent a promising tool thanks to their miniaturization, sensitivity to dielectric variations with humidity, and compatibility with flexible substrates. This study reports the design, fabrication, and metrological characterization of inkjet-printed IDEs for skin hydration monitoring, as a building block of a multisensor wearable device. IDEs were fabricated on polyimide substrates using silver nanoparticle-based ink. Their characterization involved the following: (i) morphological evaluation by scanning electron microscopy; (ii) EIS measurements in KCl solutions, leading to developing a regression model to correlate impedance with salt concentration; (iii) in vitro EIS validation on agar gel samples, which demonstrated a robust linear relationship between the impedance phase shift at 199.5 $\mathrm{Hz}$ and water loss, with consistent sensitivity values across sensors. The results confirm the feasibility of IDEs for hydration monitoring, identifying optimal frequency ranges and validating regression models. These findings represent a critical step toward the development of multisensor wearable devices for elderly monitoring, enabling decentralized and continuous health monitoring to improve healthcare sustainability and telemedicine. Full article

Additive manufacturing has promising potential for the development of 3D-printed protective structures such as stab-resistant body armor. However, no research to date has examined the impact of 3D printing parameters on the protective performance of such 3D-printed structures manufactured using fused filament fabrication technology. This study, therefore, investigates the effects of five key printing parameters: layer thickness, print speed, print temperature, infill density (Id), and layer width, on the mechanical and protective performance of 3D-printed polycarbonate (PC) armor. A Taguchi L₂₇ matrix was employed to systematically analyze these parameters, with toughness, stab penetration depth, and armor panel weight as the primary responses. ANOVA results, along with the Taguchi approach, demonstrated that Id was the most influential factor across all print parameters. This is because a higher Id led to denser structures, reduced voids and porosities, and enhanced energy absorption, significantly increasing toughness while reducing penetration depth. Morphological analysis supported the statistical findings regarding the role of Id on the performance of such structures. With optimized printing parameters, no penetration to the armor panels was recorded, outperforming the UK body armor standard of a maximum permitted knife penetration depth of 8 mm. Moreover, an artificial neural network (ANN) utilizing the 5-14-12-3 topology was created to predict the toughness, stab penetration depth, and armor panel weight of 3D-printed armors. The ANN model demonstrated better prediction performance for stab penetration depth compared to the Taguchi method, confirming the successful application of such an approach. These findings provide a critical foundation for the development of high-performance 3D-printed protective structures. Full article

This study explores the application of 3D printing as a strategic tool in engineering education and robotics development. An embedded control system for a 3D-printed MK2 manipulator is implemented, including an Arduino microcontroller, servo motors, an analog joystick interface, and an LCD, with software developed in Arduino IDE. The design uses PLA material and a modular architecture for flexibility and extensibility. The platform is applied in laboratory training to develop algorithmic thinking and engineering creativity, demonstrating the potential of 3D printing as an integrated educational and engineering tool. Full article

Mouthguards are recommended for all sports that may cause injuries to the head and oral cavity. Custom mouthguards, made conventionally in the thermoforming process from ethylene vinyl acetate (EVA), face challenges with thinning at the incisor area during the process. In contrast, additive manufacturing (AM) processes enable the precise reproduction of the dimensions specified in a computer-aided design (CAD) model. The potential use of filament extrusion materials in the fabrication of custom mouthguards has not yet been explored in comparative studies. Our research aimed to compare five commercially available filaments for the material extrusion (MEX) also known as fused deposition modelling (FDM) of custom mouthguards using a desktop 3D printer. Samples made using Copper 3D PLActive, Spectrum Medical ABS, Braskem Bio EVA, DSM Arnitel ID 2045, and NinjaFlex were compared to EVA Erkoflex, which served as a control sample. The samples underwent tests for ultimate tensile strength (UTS), split Hopkinson pressure bar (SHPB) performance, drop-ball impact, abrasion resistance, absorption, and solubility. The results showed that Copper 3D PLActive and Spectrum Medical ABS had the highest tensile strength. DSM Arnitel ID 2045 had the highest dynamic property performance, measured with the SHPB and drop-ball tests. On the other hand, NinjaFlex exhibited the lowest abrasion resistance and the highest absorption and solubility. DSM Arnitel ID 2045’s absorption and solubility levels were comparable to those of EVA, but had significantly lower abrasion resistance. Ultimately, DSM Arnitel ID 2045 is recommended as the best filament for 3D-printing mouthguards. The properties of this biocompatible material ensure high-impact energy absorption while maintaining low fluid sorption and solubility, supporting its safe intra-oral application for mouthguard fabrication. However, its low abrasion resistance indicated that mouthguards made from this material may need to be replaced more frequently. Full article

This study presents the results of optimizing FDM 3D printing parameters (layer height deposited in one pass—L_h and filling density—I_d) to enhance the mechanical performance of three-point bending specimens made from PETG and recycled PETG (rPETG). The objectives of the study are to investigate the influence of variable parameters (L_h and I_d) on the three-point bending behavior of additively manufactured specimens by thermoplastic extrusion of PETG and rPETG. It is also aims to optimize the manufacturing parameters to maximize mechanical performance, but also to evaluate the potential of using rPETG in mechanical engineering applications. The materials analyzed in this study are PETG and recycled PETG (rPETG), in the context of promoting the concept of circular economy. Using the QIDI Q1 Pro 3D printer, and the variable parameters of FDM, L_h = (0.10; 0.15; 0.20) mm and I_d = (50; 75; 100)%, 90 three-point bending specimens (45 from PETG and 45 from rPETG) were additively manufactured. To determine the mechanical strength characteristics under three-point bending stress, all 90 additively manufactured specimens were tested in three-point bending using a Barrus White 20 kN universal testing machine. The maximum bending stress is influenced by the two considered variable parameters of FDM (L_h and I_d), the parameter with the greater impact being I_d. Comparing the results of the maximum bending stresses of the additively manufactured specimens made of PETG and rPETG using the optimal parameters, it was found that the maximum bending stresses are higher in the case of the rPETG specimens, which highlights the potential of using recycled plastics in mechanical engineering applications. Full article

Background/Objectives: Hyaluronic acid (HA) is a natural substance in the human body with anti-inflammatory and healing properties that help repair bone by supporting cell growth, blood vessel formation, and tissue structure. A common complication after minimally invasive surgery is delayed bone healing in osteotomies. HA may offer a useful treatment to support faster recovery. Methods: This systematic review followed PRISMA guidelines and was pre-registered in PROSPERO (ID: CRD420250654929). Searches were conducted in PubMed, EbscoHost, Web of Science, and Scopus up to 25 January 2025. Studies from the last five years on HA and bone healing were included. The main outcomes were faster bone repair and improved regeneration. Study quality was assessed using the OCEBM, ROBINS-I, and GRADE tools. Results: Out of 96 studies, 9 met the inclusion criteria. HA, especially when combined with other materials or stem cells, helped bone repair by supporting new bone formation. Materials like 3D-printed scaffolds, hydrogels, and meshes showed good results in bone healing. However, differences in the study design made direct comparison difficult. Conclusions: Hyaluronic acid shows promise for bone repair, especially in combination with other materials. More standardized clinical trials are needed to confirm its effectiveness and define how best to use it in minimally invasive surgeries. Full article

Freeform carbon fibres were 3D-printed from CH₃OH:H₂O mixtures using hyperbaric-pressure laser chemical vapour deposition (HP-LCVD). The experiment overlapped a region of known diamond growth, with the objective of depositing diamond-like carbon without the use of plasmas or hot filaments. A high-pressure regime was investigated for the first time through the precursor’s critical point. Seventy-two C-fibres were grown from 13 different CH₃OH:H₂O mixtures at total pressures between 7.8 and 180 bar. Maximum steady-state axial growth rates of 14 µm/s were observed. Growth near the critical point was suppressed, ostensibly due to thermal diffusion and selective etching. In addition to nanostructured graphite, various carbon allotropes were synthesised at/within the outer surface of the fibres, including diamond-like carbon, graphite polyhedral crystal, and tubular graphite cones. Several allotropes were oversized compared to structures previously reported. Raman spectral pressure–temperature (P-T) maps and a pictorial P-T phase diagram were compiled over a broad range of process conditions. Trends in the Raman I_D/I_G and I_2D/I_G intensity ratios were observed and regions of optimal growth for specific allotropes were identified. It is intended that this work provide a basis for others in optimising the growth of specific carbon allotropes from methanol using HP-LCVD and similar CVD processes. Full article

This study investigates the complex relationships between process parameters and material properties in FDM-based 3D-printed biocomposites using explainable AI techniques. We examine the effects of key parameters, including biochar content (BC), layer thickness (LT), raster angle (RA), infill pattern (IP), and infill density (ID), on the tensile, flexural, and impact strengths of FDM-printed pure PLA and biochar-reinforced PLA composites. Mechanical testing was used to measure the ultimate tensile strength (UTS), flexural strength (FS), and impact strength (IS) of the 3D-printed samples. The extreme gradient boosting (XGB) algorithm was used to build a predictive model based on the data collected from mechanical testing. Shapley Additive Explanations (SHAP), Local Interpretable Model-Agnostic Explanations (LIME), and Partial Dependence Plot (PDP) techniques were implemented to understand the effects of the interactions of key parameters on mechanical properties such as UTS, FS, and IS. Prediction by XGB was accurate for UTS, FS, and IS, with R-squared values of 0.96, 0.95, and 0.85, respectively. The explanation showed that infill density has the most significant influence on UTS and FS, with SHAP values of +2.75 and +5.8, respectively. BC has the most significant influence on IS, with a SHAP value of +2.69. PDP reveals that using 0.3 mm LT and 30° RA enhances mechanical properties. This study contributes to the field of the application of artificial intelligence in additive manufacturing. A novel approach is presented in which machine learning and XAI techniques such as SHAP, LIME, and PDP are combined and used not only for optimization but also to provide valuable insights about the interaction of the process parameters with mechanical properties. Full article

Image watermarking often involves the use of handheld devices under non-structured conditions for authentication purposes, particularly in the print-cam process where smartphone cameras are used to capture watermarked printed images. However, these images frequently suffer from perspective distortions, making them unsuitable for automated information detection. To address this issue, Cam-Unet, an end-to-end neural network architecture, is presented to predict the mapping from distorted images to rectified ones, specifically tailored for print-cam challenges applied to ID images. Given the limited availability of large-scale real datasets containing ground truth distortions, we created an extensive synthetic dataset by subjecting undistorted images to print-cam attacks. The proposed network is trained on this dataset, using various data augmentation techniques to improve its generalization capabilities. Accordingly, this paper presents an image watermarking system for the print-cam process. The approach combines Fourier transform-based watermarking with Cam-Unet as perspective distortion correction. Results show that the proposed method outperforms existing watermarking approaches typically employed to counter print-cam attacks and achieves an optimal balance between efficiency and cost-effectiveness. Full article

In this study, Silicon Carbide (SiC) nanoparticle-based serigraphic printing inks were formulated to fabricate highly sensitive and wide temperature range printed thermistors. Inter-digitated electrodes (IDEs) were screen printed onto Kapton^® substrate using commercially avaiable silver ink. Thermistor inks with different weight ratios of SiC nanoparticles were printed atop the IDE structures to form fully printed thermistors. The thermistors were tested over a wide temperature range form 25 °C to 170 °C, exhibiting excellent repeatability and stability over 15 h of continuous operation. Optimal device performance was achieved with 30 wt.% SiC-polyimide ink. We report highly sensitive devices with a TCR of −0.556%/°C, a thermal coefficient of 502 K ($\beta$-index) and an activation energy of $0.08$ eV. Further, the thermistor demonstrates an accuracy of ±1.35 °C, which is well within the range offered by commercially available high sensitivity thermistors. SiC thermistors exhibit a small 6.5% drift due to changes in relative humidity between 10 and 90%RH and a 4.2% drift in baseline resistance after 100 cycles of aggressive bend testing at a 40° angle. The use of commercially available low-cost materials, simplicity of design and fabrication techniques coupled with the chemical inertness of the Kapton^® substrate and SiC nanoparticles paves the way to use all-printed SiC thermistors towards a wide range of applications where temperature monitoring is vital for optimal system performance. Full article

Flexible electronics, also referred to as printable electronics, represent an interesting technology for implementing electronic circuits via depositing electronic devices onto flexible substrates, boosting their possible applications. Among all flexible electronics, interdigitated electrodes (IDEs) are currently being used for different sensor applications since they offer significant benefits beyond their functionality as capacitors, like the generation of high output voltage, fewer fabrication steps, convenience of application of sensitive coatings, material imaging capability and a potential of spectroscopy measurements via electrical excitation frequency variation. This review examines the role of IDEs in printed and flexible electronics since they are progressively being incorporated into a myriad of applications, envisaging that the growth pattern will continue in the next generations of flexible circuits to come. Full article