Search Results (236)

This narrative review explores the role of additive manufacturing (AM) technologies in the production of dental implants, focusing on materials and key AM methods. The study discusses several materials used in implant fabrication, including porous titanium, trabecular tantalum, zirconium dioxide, polymers, and composite materials. These materials are evaluated for their mechanical properties, biocompatibility, and suitability for AM processes. Additionally, the review examines the main AM technologies used in dental implant production, such as selective laser melting (SLM), electron beam melting (EBM), stereolithography (SLA), selective laser sintering (SLS), and direct metal laser sintering (DMLS). These technologies are compared based on their accuracy, material limitations, customization potential, and applicability in dental practice. The final section presents a data source analysis of the Web of Science and Scopus databases, based on keyword searches. The analysis evaluates the research trends using three criteria: publication category, document type, and year of publication. This provides an insight into the evolution and current trends in the field of additive manufacturing for dental implants. The findings highlight the growing importance of AM technologies in producing customized and efficient dental implants. Full article

Additive manufacturing (AM) has emerged as a transformative technology in dentistry, enabling the production of patient-specific dental applications with reduced costs and fabrication times. Despite the growth of applications, a consolidated understanding of current 3D printing technologies, materials, and performance in dental settings remains fragmented. Here, we perform a Systematic Literature Review (SLR) using the PRISMA protocol, retrieving 19 closely related primary studies. The evidence is synthesized across three axes: application domain, AM technology, and critical quality parameters. Dental restorations, prosthetics, crowns, and implants are the most common applications, while fused deposition modeling, stereolithography, digital light processing, selective laser sintering, and laser-directed energy deposition are the most used technologies. AM materials include polymers, metals, and emerging biomaterials. Key quality determinants include dimensional accuracy, wear and corrosion resistance, and photosensitivity. Notably, biocompatibility and cytotoxicity remain underexplored yet critical factors for ensuring long-term clinical safety. The evidence also suggests a lack of in vivo studies, insufficient tribological and microbiological testing, including limited data degradation pathways of AM materials under oral conditions. Understanding that there are disconnects between the realization of the clinical and the economic benefits of 3D printing in dentistry, future research requires standardized testing frameworks and long-term biocompatibility validation. Full article

Background/Objectives: Recent breakthroughs in three-dimensional (3D) printing and high-resolution imaging have opened up new possibilities in personalized medicine, surgical planning, and forensic reconstruction. This study breaks new ground by evaluating the integration of high-resolution peripheral quantitative computed tomography (HR-pQCT) with multimodal imaging and additive manufacturing to assess a chronic, infected gunshot injury in the knee joint of a red deer. This unique approach serves as a translational model for complex skeletal trauma. Methods: Multimodal imaging—including clinical CT, MRI, and HR-pQCT—was used to characterise the extent of osseous and soft tissue damage. Histopathological and molecular analyses were performed to confirm the infectious agent. HR-pQCT datasets were segmented and processed for 3D printing using PolyJet, stereolithography (SLA), and fused deposition modelling (FDM). Printed models were quantitatively benchmarked through 3D surface deviation analysis. Results: Imaging revealed comminuted fractures, cortical and trabecular degradation, and soft tissue involvement, consistent with chronic osteomyelitis. Sphingomonas sp., a bacterium that forms biofilms, was identified as the pathogen. Among the printing methods, PolyJet and SLA demonstrated the highest anatomical accuracy, whereas FDM exhibited greater geometric deviation. Conclusions: HR-pQCT-guided 3D printing provides a powerful tool for the anatomical visualisation and quantitative assessment of complex bone pathology. This approach not only enhances diagnostic precision but also supports applications in surgical rehearsal and forensic analysis. It illustrates the potential of digital imaging and additive manufacturing to advance orthopaedic and trauma care, inspiring future research and applications in the field. Full article

Additive Manufacturing (AM) techniques, such as Fused Deposition Modeling (FDM) and Stereolithography (SLA), are increasingly adopted in various high-demand sectors, including the aerospace, biomedical engineering, and automotive industries, due to their design flexibility and material adaptability. However, the tribological performance and surface integrity of parts manufactured by AM are the biggest functional deployment challenges, especially in wear susceptibility or load-carrying applications. The current review provides a comprehensive overview of the tribological challenges and surface engineering solutions inherent in FDM and SLA processes. The overview begins with a comparative overview of material systems, process mechanics, and failure modes, highlighting prevalent wear mechanisms, such as abrasion, adhesion, fatigue, and delamination. The effect of influential factors (layer thickness, raster direction, infill density, resin curing) on wear behavior and surface integrity is critically evaluated. Novel post-processing techniques, such as vapor smoothing, thermal annealing, laser polishing, and thin-film coating, are discussed for their potential to endow surface durability and reduce friction coefficients. Hybrid manufacturing potential, where subtractive operations (e.g., rolling, peening) are integrated with AM, is highlighted as a path to functionally graded, high-performance surfaces. Further, the review highlights the growing use of finite element modeling, digital twins, and machine learning algorithms for predictive control of tribological performance at AM parts. Through material-level innovations, process optimization, and surface treatment techniques integration, the article provides actionable guidelines for researchers and engineers aiming at performance improvement of FDM and SLA-manufactured parts. Future directions, such as smart tribological, sustainable materials, and AI-based process design, are highlighted to drive the transition of AM from prototyping to end-use applications in high-demand industries. Full article

The article presents a three-stage methodology for calibrating 3D printing using mSLA technology, aimed at improving dimensional accuracy and print repeatability. The proposed approach is based on procedures that enable the collection and analysis of numerical data, thereby minimizing the influence of the operator’s subjective judgment, which is commonly relied upon in traditional calibration methods. In the first stage, compensation for the uneven illumination of the LCD matrix was performed by establishing a regression model that describes the relationship between UV radiation intensity and pixel brightness. Based on this model, a grayscale correction mask was developed. The second stage focused on determining the optimal exposure time, based on its effect on dimensional accuracy, detail reproduction, and model strength. The optimal exposure time is defined as the duration that provides the highest possible mechanical strength without significant loss of detail due to the light bleed phenomenon (i.e., diffusion of UV radiation beyond the mask edge). In the third stage, scale correction was applied to compensate for shrinkage and geometric distortions, further reducing the impact of light bleed on the dimensional fidelity of printed components. The proposed methodology was validated using an Anycubic Photon M3 Premium printer with Anycubic ABS-Like Resin Pro 2.0. Compensating for light intensity variation reduced the original standard deviation from 0.26 to 0.17 mW/cm², corresponding to a decrease of more than one third. The methodology reduced surface displacement due to shrinkage from 0.044% to 0.003%, and the residual internal dimensional error from 0.159 mm to 0.017 mm (a 72% reduction). Full article

New materials for additive manufacturing are currently being actively studied, which both have the necessary physicochemical properties and are safe for the environment and living organisms. We have proposed a simple process for the production of composite materials based on a transparent polymethyl methacrylate-like photopolymer resin modified with metallic titanium nanoparticles. Standardized plate samples were printed from the obtained modified photopolymer resins using mask stereolithography with an LED light source array (MSLA), and their mechanical properties were evaluated. Plates were also printed, for which the surface topology, distribution of nanoparticles in the polymer matrix, chemical structure, optical properties, chemical structure, and optical properties were characterized. In the context of the impact on biological systems, the ability of materials to enhance the formation of ROS and affect the main biomacromolecules was demonstrated. At the same time, the developed composite materials inhibit the growth of E. coli bacterial cells, and the bactericidal effect of the surfaces of the obtained materials was shown. Despite the significant antibacterial properties of the synthesized materials, no negative impact on the growth and development of adhesive cultures of eukaryotic cells in vitro was detected. Full article

Background: Stereolithography is a rapid prototyping and 3D printing technique that creates solid three-dimensional models. An accurate and functional 3D model using stereolithography is invaluable in scientific research, particularly in studies involving edentulous patients. Additive manufacture and CAD systems help achieve accurate measurements and procedures and be easily replicated by lowering human error mistakes. The main objective of this study was to develop an in vitro simulation model with a reduced alveolar ridge with the same characteristics as mandibular edentulous patients using stereolithography. Methods: A mandibular model with a resorbed mandibular crest was scanned, and the STL model was aligned to the XYZ reference system. A reduction in the alveolar ridge corresponding to the mandibular mucosa of an edentulous patient was achieved. A negative model also derived from the original model was made to ensure the space for oral simulation material. A dimensional stability test was performed to validate the model. Results: The maximal mean displacement of the model was 0.015 mm, and the minimal mean displacement was 0.004 mm. The oral mucosa had a displacement of approximately 1.6 mm. Conclusions: An in vitro 3D simulation model of a complete edentulous patient mucosa was achieved. Full article

This study aims to establish a methodology that integrates experimental measurements with finite element analysis (FEA) to investigate the mechanical behavior and dynamic characteristics of soft–hard laminated composites fabricated via additive manufacturing (AM) under dynamic excitation. A hybrid AM technique was employed, using the PolyJet process based on stereolithography (SLA) to fabricate composite beam structures composed of alternating soft and hard materials. Initially, impact tests using a steel ball on cantilever beams made of hard material were conducted to inversely calculate the first natural frequency via time–frequency analysis, thereby identifying Young’s modulus and Poisson’s ratio. For the viscoelastic soft material, tensile and stress relaxation tests were performed to construct a Generalized Maxwell Model, from which the Prony series parameters were derived. Subsequently, symmetric and asymmetric multilayer composite beams were fabricated and subjected to impact testing. The experimental results were compared with FEA simulations to evaluate the accuracy and validity of the identified material parameters of different structural configurations under vibration modes. The research focuses on the time- and frequency-dependent stiffness response of the composite by hard and soft materials and integrating this behavior into structural dynamic simulations. The specific objectives of the study include (1) establishing the Prony series parameters for the soft material integrated with hard material and implementing them in the FE model, (2) validating the accuracy of resonant frequencies and dynamic responses through combined experimental and simulation, (3) analyzing the influence of composite material symmetry and thickness ratio on dynamic modals, and (4) comparing simulation results with experimental measurements to assess the reliability and accuracy of the proposed modeling framework. Full article

Crash boxes play a vital role in improving vehicle safety by absorbing collision energy and reducing the forces transmitted to occupants. Additive manufacturing (AM) has become a powerful method for developing advanced crash boxes by enabling complex geometries. This review provides a comprehensive examination of recent progress in AM crash boxes, with a focus on three key aspects: geometric design innovations, material behavior, and manufacturing techniques. The review investigates the influence of various AM-enabled structural configurations, including tubular, origami-inspired, lattice, and bio-inspired designs, on crashworthiness performance. Among these, bio-inspired structures exhibit superior energy absorption characteristics, achieving a mean specific energy absorption $\left(SEA\right)$ of 21.51 J/g. Material selection is also explored, covering polymers, fiber-reinforced polymers, metals, and multi-material structures. Metallic AM crash boxes demonstrate the highest energy absorption capacity, with a mean $SEA$ of 28.65 J/g. In addition, the performance of different AM technologies is evaluated, including Stereolithography (SLA), Material Jetting (MJT), Selective Laser Melting (SLM), Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM), and hybrid manufacturing techniques. Among these, crash boxes produced by SLM show the most favorable energy absorption performance, with a mean $SEA$ of 16.50 J/g. The findings presented in this review offer critical insights to guide future research and development in the design and manufacturing of next-generation AM crash boxes intended to enhance vehicle safety. Full article

This paper is focused on the modification of commercial resin by using biobased fillers during stereolithography (SLA) 3D printing. This research aims to create a composite material with a matrix made of commercially available photosensitive resin modified with a filler based on secondary raw materials and materials formed as by-products in the processing of biological materials. The research determines the effect of different fillers on the tensile properties and hardness of samples printed using SLA 3D printing, and it also investigates their integrity using SEM analysis. This study aims to evaluate the feasibility of using these fillers for producing 3D-printed parts with SLA technology. The results of this study open up new possibilities for designing modified composite materials based on additive SLA 3D-printing technology using biological fillers. Within the framework of research activities, a positive effect on tensile properties and an improved interfacial interface between the matrix and the filler was demonstrated for several tested fillers. Significant increases in tensile strength of up to 22% occurred in composite systems filled with cotton flakes (CF), miscanthus (MS), walnut (WN), spruce tree (SB), wheat (WT) and eggshells (ES). Significant potential for further research activities and added value was shown by most of the tested bio-fillers. A significant contribution of the current research is the demonstration of the improved mechanical performance of photosensitive resin modified with natural fillers. Full article

This study investigated the feasibility and effectiveness of a commercial top-down stereolithography (SLA)-based system for the additive manufacturing of zirconia dental prostheses. Yttria-stabilized zirconia–resin slurries were prepared, and zirconia objects were fabricated using a top-down SLA system. Thermogravimetric–differential thermal analysis was used to examine the resin, while X-ray fluorescence spectroscopy and X-ray diffraction were used to analyze the printed samples. The microstructures of additively manufactured and subtractively manufactured zirconia were compared using field emission scanning electron microscopy (FE-SEM) before and after sintering. Biaxial flexural strength tests were also conducted to evaluate mechanical properties. The green bodies obtained via additive manufacturing exhibited uniform layering with strong interlayer adhesion. After sintering, the structures were dense with minimal porosity. However, compared to subtractively manufactured zirconia, the additively manufactured specimens showed slightly higher porosity and lower biaxial flexural strength. The results demonstrate the potential of SLA-based additive manufacturing for dental zirconia applications while also highlighting its current mechanical limitations. The study also showed that using a blade to evenly spread viscous slurry layers in a top-down SLA system can effectively reduce oxygen inhibition at the surface and relieve internal stresses during the layer-by-layer printing process, offering a promising direction for clinical adaptation. Full article

Stereolithography (SLA) is a popular additive manufacturing (AM) method frequently used in research and various industrial sectors. The acrylate resin used in this research is renowned for its flexibility and durability, enabling the creation of flawless 3D-printed parts with exceptional mechanical properties. This study aims to enhance the thermomechanical properties of 3D-printed hollow glass microballoon (HGM)-filled composite materials by adding minimal HGM into the acrylate resin. We investigated the material properties through uniaxial compression tests, dynamic mechanical analysis (DMA), and scanning electron microscopy (SEM). To validate the results, a numerical investigation and a machine learning (ML) approach were carried out and compared with the experimental results. Adding a small number of microballoons increases compressive strength and stiffness. The viscoelastic behavior of the samples also provides an estimate of resilience at higher temperatures, considering the addition of filler material into the resin. Our study shows that the addition of 0.04% of HGM increased compressive strength by around 99.30% compared to the neat sample, while the stiffness increased by around 31.42% compared to the neat sample at 0.05% of HGM. It can also be estimated that the suitable range of HGM addition for the resin we used exists between 0.04% and 0.05%, where the materials achieve their maximum strength and stiffness. In addition, a predictive machine learning (ML) model, namely Random Forest Regressor (RFR), shows low mean squared error (MSE), mean absolute error (MAE), and excellent R² scores, demonstrating the goodness of the model’s performance. This modern approach can guide us to selecting a suitable filler percentage for the photopolymer resin for 3D printing and making it applicable to different engineering prospects. Full article

Alumina is a polycrystalline oxide ceramic with different structures. Currently, α-alumina with a hexagonal close-packed stacking structure is mainly used for a variety of industrial applications. Alumina-based ceramics and composites have been widely used in various fields due to their excellent hardness, strength, creep resistance and good biocompatibility. However, it is difficult for Al₂O₃ ceramic components based on traditional preparation methods to meet the increasing industrial requirements, especially for applications such as precise multi-walled complex structures. Al₂O₃ ceramic additive manufacturing by vat photopolymerization 3D printing stands out owing to its ability to produce complex structures and tailored shaping accuracy/properties. The vat photopolymerization 3D printing of Al₂O₃ ceramics requires multiple steps including slurry preparation, photopolymerization shaping, debinding and sintering. Therefore, many efforts mainly focus on the strategies of optimizing the ceramic slurry formulation and the debinding/sintering process. This paper provides a scoping review to present optimization strategies for the above aspects of vat photopolymerization 3D printing, which creates a strong reference for researchers to improve the accuracy and properties of alumina parts. Finally, this review also states the main applications of Al₂O₃ ceramic components based on vat photopolymerization, and highlights the opportunities and challenges associated with this technology in the future. It is beneficial to understanding the future trends and policy directions of advanced manufacturing industry. Full article

As additive manufacturing technologies continue to gain ground in industrial applications, the need for the accurate metrological evaluation of parts produced with advanced materials becomes increasingly critical. In this context, non-contact metrology plays a key role. This research investigates the performance of conoscopic holography as an optical metrology technique for the inspection of ceramic parts manufactured by stereolithography. However, its reliability needs to be validated, especially as factors such as material properties, surface finish, and color can significantly affect measurement accuracy. Spherical artifacts in alumina were chosen as mathematically well-defined reference elements, and a representative series was produced with the best values for the printing, debinding, and sintering parameters. These spheres were first measured via contact with a coordinate measuring machine (CMM) to establish dimensional (diameter) and geometrical (form error) reference values. These parameters were then compared with measurements obtained via conoscopic holography and optimized by means of Gaussian filters. The results indicated significant dimensional (up to 60 µm) and geometrical (up to 280 µm) deviations from the CMM reference data. The investigation shows that conoscopic holography does not ensure an accurate measurement method for this additive process and ceramic material, making it impossible to achieve power and frequency settings that would allow signal-to-noise ratios above 50%. Full article

The development of microtextures has had a transformative impact on surface design in engineering, leading to substantial advancements in the performance, efficiency, and functionality of components and tools. This study presents an innovative methodology for fabricating SEDM electrodes. The methodology combines additive manufacturing by mask stereolithography with an optimized electroforming process to obtain high-precision copper shells. A key aspect of the study involved redesigning the electroforming equipment, enabling the independent examination of critical variables such as anode–cathode distance and electrolyte recirculation. This approach allowed precise analysis of their impact on metal deposition. This redesign enabled the assessment of the impact of electrolyte recirculation on the quality of the shells obtained. The findings indicate that continuous recirculation at 60% power effectively reduced thickness deviation by up to 32.5% compared to the worst-case scenario, achieving average thicknesses within the functional zone of approximately 110 µm. In contrast, the absence of flow or excessive turbulence did not generate defects such as unfilled zones or non-uniform thicknesses. The shells obtained were validated as functional tools in SEDM, demonstrating their viability for the generation of textures with high geometric fidelity. This approach optimizes the manufacturing of textured electrodes and opens new opportunities for their application in advanced industrial processes, providing a more efficient and sustainable alternative to conventional methods. Full article