Search Results (1,002)

Introduction: 3D-printing is an emerging technology in the field of prosthetics, offering advantages such as cost-effectiveness, ease of customization, and improved accessibility. While previous reviews have focused on limited aspects, the aim of this systematic review is to provide a comprehensive evaluation of the clinical outcomes of 3D-printed prostheses for both upper and lower limbs. Methods: A search was conducted following Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) guidelines across six databases (PubMed, Web of Science, EBSCO, Scopus, Cochrane Library, and Sage). Studies on 3D-printed prostheses in human rehabilitation that focused on the clinical outcomes of the device were included, while studies lacking clinical data, 3D printing details, or focusing on traditional manufacturing methods were excluded. Finally, the risk of bias was assessed using the modified Downs & Black Checklist. Results: A total of 1420 studies were identified, with 11 meeting the inclusion criteria. The included studies assessed different 3D-printed prosthetic types and upper and lower limb prostheses. The main clinical outcomes analyzed were functional performance, design and material integrity, and overall effectiveness of 3D-printed prostheses. Studies on upper limb prostheses reported improved dexterity, range of motion (ROM), and user satisfaction, despite some durability limitations. Lower limb prostheses showed enhancements in comfort, gait parameters, and customization, particularly in amphibious and partial foot designs. Conclusions: 3D-printed prostheses show potential to improve functional performance, patient satisfaction, fit, and implementation feasibility compared to conventional methods. However, limitations such as small sample sizes, variability in assessment tools, and limited high-quality evidence highlight the need for further research to support broader clinical adoption. Full article

Background/Objectives: This study investigates the dosimetric impact of a 3D-printed applicator integrating multilayer catheter geometry and high-density shielding, designed for contact interventional radiotherapy (IRT) in non-melanoma skin cancer (NMSC) treatment. The aim is to assess its potential to enhance target coverage and reduce doses in organs at risk (OARs). Methods: A virtual prototype of a multilayer applicator was designed using 3D modeling software and realized through fused deposition modeling. Dosimetric simulations were performed using both TG-43 and TG-186 formalisms on CT scans of a water-equivalent phantom. A five-catheter array was reconstructed, and lead-cadmium-based alloy shielding of varying thicknesses (3–15 mm) was contoured. CTVs of 5 mm and 8 mm thickness were analyzed along with a neighboring OAR. Dosimetric endpoints included V95%, V100%, V150% (CTV), D_2cc (OAR), and therapeutic window (TW). Results: Compared to TG-43, the TG-186 algorithm yielded lower OAR doses while maintaining comparable CTV coverage. Progressive increase in shielding thickness led to improved V95% and V100% values and a notable reduction in OAR dose, with an optimal trade-off observed between 6 and 9 mm of shielding. The TW remained above 7 mm across all configurations, supporting its use in lesions thicker than conventional guidelines recommend. Conclusions: The integration of multilayer catheter geometry with high-density shielding in a customizable 3D-printed applicator enables enhanced dose modulation and OAR sparing in superficial IRT. This approach represents a step toward personalized brachytherapy, aligning with the broader movement in radiation oncology toward patient-specific solutions, adaptive planning, and precision medicine. Future directions should include prototyping and mechanical testing of the applicator, experimental dosimetric validation in phantoms, and pilot clinical feasibility studies to translate these promising in silico results into clinical practice. Full article

Three-dimensional printing has enabled the production of complex parts that are difficult to create with conventional manufacturing methods. Its additive nature has made it possible to create interconnected (assembled) parts in a single manufacturing step. This requires the development of new ways of designing, manufacturing, and testing mechanisms that do not require assembly after their creation, called non-assembly mechanisms. An approach is proposed for the design and experimental study of the properties of rotational joints created already assembled using FFF technology for 3D printing. The advantages and disadvantages of different 3D printing methods that can be used to obtain such assemblies are discussed. Basic principles for the design of assembled rotational joints, built without support structures, are introduced. Two examples of their application in creating functional robot models are presented. The features during production, and the advantages and disadvantages of the models are discussed. Models of directly assembled rotational joints with different clearances are studied, and an experiment is conducted based on measuring the magnitude of the current during the rotation of a link. This provides indirect results for the rolling resistance, on the basis of which the qualities of the joint are judged. The results from the experiments show that rotational joints with a diameter d = 10 [mm], created using FFF technology and PLA material, have the lowest resistance at a clearance in the range t = 0.15–0.25 [mm]. Full article

Background: Congenital talipes equinovarus (clubfoot) affects 1–2 per 1000 newborns worldwide. The Ponseti method, based on staged manipulations and casting, is the gold standard for correction. However, the biomechanical processes underlying these corrections remain poorly understood, as infants rarely undergo imaging. Computational modeling may offer a non-invasive approach to studying correction pathways and exploring novel applications, such as customized casts. Methods: We developed a proof-of-concept framework using iterative finite element analysis (iFEA) to approximate the surface-level geometric corrections targeted in Ponseti treatment. A 3D surface model of a training clubfoot foot was scanned, meshed, and deformed stepwise under applied computational loads. The model was assumed to be homogeneous and hyperelastic, and correction was quantified using Cavus, Adductus, Varus, Equinus, and Derotation angles. We also introduced a secondary adult leg 3D surface model to assess whether model simplification influences correction outcomes, by comparing a homogeneous soft tissue model with a non-homogeneous model incorporating bone structure. Results: In the training model, iFEA generated progressive deformations consistent with Ponseti correction, with mean angular deviations of ±3.2°. In the adult leg model, homogeneous and non-homogeneous versions produced comparable correction geometries, differing by <2° in outcomes. The homogeneous model required less computation, supporting its use for feasibility testing. Applied loads were computational drivers, not physiological forces. Conclusions: This feasibility study shows that iFEA can reproduce surface-level geometric changes consistent with Ponseti correction, independent of model homogeneity. While not replicating clinical biomechanics, this framework lays the groundwork for future work that incorporates clinician-applied forces, pediatric tissue properties, and patient-specific geometries, with potential applications in customized 3D-printed casts. Full article

This study aimed to evaluate the scientific reliability of 3D-printed silicone boluses fabricated with patient-specific molds, focusing on fabrication-related uncertainties such as internal air bubbles, thickness variations, and density differences, thereby providing evidence for clinical quality assurance. Custom silicone boluses were fabricated using 3D-printed molds with varying vacuum degassing times (1, 5, and 10 min). Air bubble size and depth were quantified using scanner image analysis, while density and Hounsfield unit (HU) values were compared with a commercial bolus. Dosimetric evaluation was performed using a VitalBeam linear accelerator (6 MV photons, Varian Medical Systems, Palo Alto, CA, USA) and a MatriXX 2D detector (IBA Dosimetry, Schwarzenbruck, Germany), comparing treatment planning system (TPS) calculated doses with measured doses across a 3 × 3 grid. Surface dose distributions were further analyzed using EBT3 film. Results showed that bubble size increased with longer vacuum times, interpreted as coalescence due to limited degassing and silicone viscosity. The density of 3D boluses ranged from 0.980 to 1.104 g/cm³ (commercial: 0.988 g/cm³), with HU values of +240 to +250 (commercial: −110). In point-wise comparisons, mean dose differences were less than 1% for 1- and 5 min samples and approximately 1% for 10 min, with all conditions within |Δ| ≤ 3%. Film analysis confirmed equivalent surface dose distributions. These findings demonstrate, for the first time, that microscopic bubbles in 3D-printed silicone boluses have negligible clinical impact, supporting their safe adoption without requiring complex degassing procedures. Full article

This study presents a viscosity-controlled epoxy infiltration strategy to mitigate common production defects, such as interlayer bond weaknesses, step gaps, and surface roughness, in 3D-printed polypropylene lattice and tube structures. To address these issues, epoxy resin infiltration was applied at four distinct viscosity levels. The infiltration process, facilitated by ultrasonic assistance, improved epoxy penetration into the internal structure. The results indicate that this method effectively reduced micro-voids and surface irregularities. Variations in epoxy viscosity significantly influenced the final internal porosity and the thickness of the epoxy film formed on the surface. These structural changes directly affected the energy absorption (EA) and specific energy absorption (SEA) of the specimens. While performance was enhanced across all viscosity levels, the medium-viscosity specimens (L-V2 and L-V3), with a mass uptake of ~37%, yielded the most favorable outcome, achieving high SEA (0.84 J/g) and EA (252 J) values. This improvement was mainly attributed to the epoxy filling internal voids and defects. Mechanical test results were further supported by SEM observations and validated through statistical correlation analyses. This work constitutes one of the first comprehensive studies to employ epoxy infiltration for defect mitigation in 3D-printed polypropylene structures. The proposed method offers a promising pathway to enhance the performance of lightweight, impact-resistant 3D-printed structures for advanced engineering applications. Full article

This study addresses critical bottlenecks in photocatalytic water treatment technologies, including difficulties in recovering traditional powdered catalysts, low mass transfer efficiency in immobilized reactors, and limited structural diversity. By integrating topology optimization with 3D printing technology, we designed and fabricated five types of triply periodic minimal surface photocatalytic reactors (TPMS-PCRs) with hierarchical porous structures—Fischer-Radin-Dunn (FRD), Neovius (N), Diamond (D), I-graph Wrapped Package (IWP) and Gyroid (G). Using fused deposition modeling (FDM), these TPMS configurations were manufactured from polylactic acid (PLA), 1.5 wt% TiO₂/PLA, and 2.5 wt% TiO₂/PLA. The catalytic degradation performance of these structurally distinct reactors for organic pollutants varied significantly. Notably, the FRD-type TPMS-PCR loaded with 2.5 wt% TiO₂ achieved a methylene blue (MB) degradation rate of 93.4% within 2.5 h under rotational flow conditions, compared to 87.5% under horizontal flow conditions. Full article

Schatzker type V bicondylar tibial plateau fractures present a major challenge due to the difficulty of achieving stable fixation with minimally invasive strategies. This study introduces a dual-thread lag and locking plate (DLLP) design that integrates lag screw compression with unilateral locking plate fixation. A custom-built compression evaluation platform and standardized 3D-printed fracture models were employed to assess biomechanical performance. DLLP produced measurable interfragmentary compression during screw insertion, with a mean displacement of 1.22 ± 0.11 mm compared with 0.02 ± 0.04 mm for conventional single lateral locking plates (SLLPs) (p < 0.05). In static testing, DLLP demonstrated a significantly greater maximum failure force (7801.51 ± 358.95 N) than SLLP (6224.84 ± 411.20 N, p < 0.05) and improved resistance to lateral displacement at 2 mm (3394.85 ± 392.81 N vs. 2766.36 ± 64.51 N, p = 0.03). Under dynamic fatigue loading simulating one year of functional use, all DLLP constructs survived 1 million cycles with <2 mm displacement, while all SLLP constructs failed prematurely (mean fatigue life: 408,679 ± 128,286 cycles). These findings highlight the critical role of lag screw compression in maintaining fracture stability and demonstrate that DLLP provides superior biomechanical performance compared with SLLP, supporting its potential as a less invasive alternative to dual plating in the treatment of complex tibial plateau fractures. Full article

Optimizing printing parameters is crucial for enhancing the efficiency, surface quality, and dimensional accuracy of Fused Deposition Modeling (FDM) processes. A review of numerous publications reveals that most scholars analyze factors such as nozzle diameter and printing speed, while few investigate the impact of layer thickness, infill density, and shell layer count on print quality. Therefore, this study employed 3D slicing software to process the three-dimensional model and design printing process parameters. It systematically investigated the effects of layer thickness, infill density, and number of shells on printing time and geometric accuracy, quantifying the evaluation through volumetric error. Using an ABS connecting rod model, optimal parameters were determined within the defined range through orthogonal experimental design and signal-to-noise ratio (S/N) analysis. Subsequently, a backpropagation (BP) neural network was constructed to establish a predictive model for process optimization. Results indicate that parameter selection significantly impacts print duration and surface quality. Validation confirmed that the combination of 0.1 mm layer thickness, 40% infill density, and 5-layer shell configuration achieves the highest dimensional accuracy (minimum volumetric error and S/N value). Under this configuration, the volumetric error rate was 3.062%, with an S/N value of −9.719. Compared to other parameter combinations, this setup significantly reduced volumetric error, enhanced surface texture, and improved overall print precision. Statistical analysis indicates that the BP neural network model achieves a Mean Absolute Percentage Error (MAPE) of no more than 5.41% for volume error rate prediction and a MAPE of 5.58% for signal-to-noise ratio prediction. This validates the model’s high-precision predictive capability, with the established prediction model providing effective data support for FDM parameter optimization. Full article

Background: Three-dimensional (3-D) printing paired with tissue-engineering strategies promises to overcome the volume, contour, and donor-site limitations of traditional breast reconstruction. Patient-specific, bioabsorbable constructs could enable one-stage procedures that better restore aesthetics and sensation. Methods: A narrative review was conducted following a targeted PubMed search (inception—April 2025) using combinations of “breast reconstruction,” “tissue engineering,” “3-D printing,” and “scaffold.” Pre-clinical and clinical studies describing polymer-based chambers or scaffolds for breast mound or nipple regeneration were eligible. Data was extracted on scaffold composition, animal/human model, follow-up, and volumetric or histological outcomes. Results: Forty-three publications met inclusion criteria: 35 pre-clinical, six early-phase clinical, and two device reports. The predominant strategy (68% of studies) combined a vascularized fat flap with a custom 3-D-printed chamber to guide adipose expansion. Poly-lactic acid, poly-glyceric acid, poly-lactic-co-glycolic acid, poly-4-hydroxybutyrate, polycarbonate, and polycaprolactone were the principal polymers investigated; only poly-4-hydroxybutyrate and poly-lactic acid have been tested for nipple scaffolds. Bioabsorbable devices supported up to 140% volume gain in large-animal models, but even the best human series (≤18 months) achieved sub-mastectomy volumes and reported high seroma rates. Mechanical testing showed elastic moduli (5–80 MPa) compatible with native breast tissue, yet long-term load-bearing data are scarce. Conclusions: Current evidence demonstrates biocompatibility and incremental adipose regeneration, but clinical translation is constrained by small sample sizes, incomplete resorption profiles, and regulatory uncertainty. Standardized large-animal protocols, head-to-head polymer comparisons, and early human feasibility trials with validated outcome measures are essential next steps. Nevertheless, the convergence of 3-D printing and tissue engineering represents a paradigm shift that could ultimately enable bespoke, single-stage breast reconstruction with superior aesthetic and functional outcomes. Full article

The growing interest in smart buildings and the integration of IoT-based technologies is driving the development of new tools for monitoring and optimizing indoor environmental quality (IEQ). However, many existing solutions remain expensive, invasive and inflexible. This paper presents the design and validation of a compact, low-cost, and real-time sensor system, conceived for seamless integration into indoor environments. The system measures key parameters—including air temperature, relative humidity, illuminance, air quality, and sound pressure level—and is embeddable in standard office equipment with minimal impact. Leveraging 3D printing and open-source hardware/software, the proposed solution offers high affordability (approx. EUR 33), scalability, and potential for workspace retrofits. To assess the system’s performance and relevance, dynamic simulations were conducted to evaluate metrics such as the Mean Radiant Temperature (MRT) and illuminance in an open office layout. In addition, field tests with a functional prototype enabled model validation through on-site measured data. The results highlighted significant local discrepancies—up to 6.9 °C in MRT and 28 klx in illuminance—compared to average conditions, with direct implications for thermal and visual comfort. These findings demonstrate the system’s capacity to support high-resolution environmental monitoring within IoT-enabled buildings, offering a practical path toward the data-driven optimization of occupant comfort and energy efficiency. Full article

The increasing demand for novel tissue engineering (TE) applications in bone tissue regeneration underscores the importance of exploring advanced manufacturing techniques and biomaterials for personalised treatment approaches. Three-dimensional printing (3DP) technology facilitates the development of implantable devices with intricate geometries, enabling patient-specific therapeutic solutions. Although Fused Filament Fabrication (FFF) and Direct Ink Writing (DIW) are widely utilised for fabricating bone-like implants, the need for multiple processing steps often prolongs the overall production time. In this study, a single-step melt-extrusion 3DP technique was performed to develop multi-material scaffolds including bioceramics, hydroxyapatite (HA), and β-tricalcium phosphate (TCP) in both their bioactive and calcined forms at 10% and 20% w/w, within polycaprolactone (PCL) matrices. Printing parameters were optimised, and physicochemical properties of all biomaterials and final forms were evaluated. Thermal degradation and surface morphology analyses assessed the consistency and distribution of the ceramics across the different formulations. The tensile testing of the scaffolds defined the impact of each ceramic type and wt% on scaffold flexibility performance, while in vitro cell studies determined the cytocompatibility efficiency. Hence, all 3D-printed PCL–ceramic composite scaffolds achieved structural integrity and physicochemical and thermal stability. The mechanical profile of extruded samples was relevant to the ceramic consistency, providing valuable insights for further mechanotransduction investigations. Notably, all materials showed high cell viability and proliferation, indicating strong biocompatibility. Therefore, this additive manufacturing (AM) process is a precise and fast approach for developing biomaterial-based scaffolds, with potential applications in surgical restoration and support of segmental bone defects. Full article

Amorphous solid dispersions (ASDs) provide an effective approach to overcome the poor solubility of many active pharmaceutical ingredients and can facilitate their uniform distribution within hydrogel matrices. Although ASDs are well recognized in oral formulations, their use with hydrogels for wound care remains underexplored. Hydrogels not only offer a biocompatible environment for healing wounds but also are highly versatile for 3D printing, enabling the design of patient-specific dressings customized in composition and structure. This review emphasizes the therapeutic potential of combining ASDs with hydrogel platforms, focusing on how these systems can speed up wound healing, minimize complications, and support personalized therapies. The physicochemical basis for amorphization with limitations and the synergistic effects of bioactive hydrogels are discussed to provide a conceptual basis for advancing this innovative strategy in chronic wound treatment. Full article

Particle-based 3D printing shows great potential in high-performance composite fabrication due to high raw material utilization and flexible material compatibility. However, constrained by conventional extrusion system structures, critical issues (non-uniform melt conveying, insufficient mixing efficacy, poor extrusion stability, etc.) remain. To address these, this study proposes a novel separate-type pin screw integrating solid–liquid separation (from split screws) and high-efficiency mixing (from pin screws) to improve CF/PLA composite extrusion efficiency and mixing homogeneity in particle-based 3D printing. Three-dimensional modeling, static strength/stiffness analysis, and POLYFLOW-based numerical simulation of particle melt conveying/mixing in the screw channel were conducted to analyze structural parameter effects on pressure field, shear rate, and mixing. Experiments assessed printer extrusion rate (different screws) and printed specimen mechanical properties. The simulation and experiment confirmed the optimized screw has better pressure distribution and mixing at 20 rpm, with optimal pin parameters: diameter 2 mm, height 1.6 mm, radial angle 60°, and axial spacing 10 mm. This work offers theoretical/structural support for particle-based 3D printing extrusion system optimization. Full article

Improving energy efficiency in buildings is critical for supporting sustainable growth in the construction sector. In this context, the implementation of passive solar solutions in the building envelope plays an important role. Trombe wall is a passive solar system that presents great potential for passive solar heating purposes. However, its performance can be enhanced when the Internet of Things is applied. This study employs a multi-domain smart system based on Matter-enabled IoT technology for maximizing Trombe wall functionality using appropriate 3D-printed ventilation grids. The system includes ESP32-C6 microcontrollers with temperature sensors and ventilation grids controlled by actuated servo motors. The system is automated with a Raspberry Pi 5 running Home Assistant OS with Matter Server. The integration of the Matter protocol provides end-to-end interoperability and secure communication, avoiding traditional systems based on MQTT. This work demonstrates the technical feasibility of implementing smart ventilation control for Trombe walls using a Matter-enabled infrastructure. The system proves to be capable of executing real-time vent management based on predefined temperature thresholds. This setup lays the foundation for scalable and interoperable thermal automation in passive solar systems, paving the way for future optimizations and addicional implementations, namely in order to improve indoor thermal comfort in smart and more efficient buildings. Full article