Electrospinning on 3D Printed Polymers for Mechanically Stabilized Filter Composites

Evaluating the efficacy of uniformly designed square mesh resin 3D printed scaffolds in directing the orientation of electrospun PCL nanofibers

Replicating the architecture of extracellular matrices (ECM) is crucial in tissue engineering to support tissues' natural structure and functionality. The ECM's structure plays a significant role in directing cell alignment. Electrospinning is an effective technique for fabricating nanofibrous substrates that mimic the architecture of extracellular matrices (ECM). This study aims to evaluate the efficacy of resin 3D-printed scaffolds made from a low-conductivity material (i.e., a resin composed of methacrylated oligomers, monomers, and photoinitiators) in directing the alignment of electrospun polycaprolactone (PCL) nanofibers. Six 3D-printed scaffolds were fabricated using stereolithography (SLA) technology and strategically positioned on an aluminum foil collector plate during electrospinning. The structured geometry of the scaffolds, rather than the local electric field distribution, is hypothesized to guide nanofiber alignment. Images acquired through the scanning electron microscopy (SEM) were used to analyze and statistically quantify the nanofibrous scaffolds to evaluate the alignment of nanofibers over the scaffolds compared to a set of randomly deposited control nanofiber samples in the absence of the 3D printed scaffolds. SEM images also showed significant alignment of nanofibers within the pores of scaffolds, using histograms as a means for indicating the distribution of orientation angles. Statistical analysis revealed that this distribution deviates from normality due to the deviations in the tails and the existence of relatively smaller peaks at angles relative to 0°, particularly within a range of ± 50° and ± 40°. It is further found that the average peak orientation angle relative to 0° had a maximum probability of 0.014. Furthermore, the statistical analysis confirmed the distribution and significant differences in orientation between test samples with 3D-printed scaffolds and control samples. These findings demonstrate the effectiveness of resin 3D-printed scaffolds, particularly their geometric filtering effect, leading to controlled nanofiber alignment, which is proposed to be beneficial for enhancing cell adhesion, proliferation, and cell migration in tissue engineering applications.

Hyperbranched polymeric membranes for industrial water purification

This work aims at the preparation and characterization of dual-layer (DL) nano-fibrous mat (NFM) of hydrophobic and mechanical stable polyacrylonitrile (PAN) nano-fibers (NFs), as a supporter, and polyamide 6 (PA)/chitosan (Ch) NFs as a top hydrophilic coating layer. PAN and PA fibers, as residual wastes from textile processes, were collected and dissolved in their proper solvents. PAN was electro-spuned under certain conditions of electro-spinning (voltage, flow rate, and distance between spinneret and collector) to obtain PAN-NFM. Different ratios of PA/Ch composite were prepared and then electro-spun above the PAN-NFM that was previously prepared to obtain hydrophobic/hydrophilic functional dual-layer nano-fibrous membrane (DLNFM). The efficiency of the prepared DLNFM for capturing dye residues and heavy metals from wastewater was investigated. The viscosities of the prepared composite solutions were measured. The prepared dual-layer nano-fiber membranes (DLNFMs) were chemically and physically characterized by Fourier transform infrared spectroscopy, scanning electron microscope, X-ray diffraction, and thermogravimetric analyzer. The potential of the prepared mats for the adsorption of some heavy metal ions, i.e., Cu+2, Cr+3, and Pb+2 cations in addition to dyes from wastewater was evaluated. The effect of using different concentrations of PA/Ch composite as well as the thickness of the obtained DLNFM on the filtration efficiency was studied. The results of this study show the success of functional DLNFM in dye and heavy metal removal. The maximum removal efficiency of acid dyes was reached to 73.4 % and of reactive dye was approximately 61 % for PAN/PA-1.25%Ch DLNFM after 3 days at room temperature. The removal efficiency percent of heavy metal ions reached to 54 % by DLNFM. Additionally, the results showed that 0.08 mm is the ideal thickness for maximum absorption capacity. This value is correlated with the membrane's highest Ch percentage, which is (PAN/PA-1.25%Ch). Furthermore, the results demonstrate that the presence of the Ch polymer strengthened the produced bi-layered membrane to achieve the highest thermal stability when compared to the other nano-fibrous membranes (NFMs), with the breakdown temperature of the Ch functionalized dual-layer membranes (DLMs) reaching approximately 617 °C and a maximum weight loss of 60 %.

PVA-Based Electrospun Materials-A Promising Route to Designing Nanofiber Mats with Desired Morphological Shape-A Review

Poly(vinyl alcohol) is one of the most attractive polymers with a wide range of uses because of its water solubility, biocompatibility, low toxicity, good mechanical properties, and relatively low cost. This review article focuses on recent advances in poly(vinyl alcohol) electrospinning and summarizes parameters of the process (voltage, distance, flow rate, and collector), solution (molecular weight and concentration), and ambient (humidity and temperature) in order to comprehend the influence on the structural, mechanical, and chemical properties of poly(vinyl alcohol)-based electrospun matrices. The importance of poly(vinyl alcohol) electrospinning in biomedical applications is emphasized by exploring a literature review on biomedical applications including wound dressings, drug delivery, tissue engineering, and biosensors. The study also highlights a new promising area of particles formation through the electrospraying of poly(vinyl alcohol). The limitations and advantages of working with different poly(vinyl alcohol) matrices are reviewed, and some recommendations for the future are made to advance this field of study.

3D-Printed Materials for Wastewater Treatment

The increasing levels of water pollution pose an imminent threat to human health and the environment. Current modalities of wastewater treatment necessitate expensive instrumentation and generate large amounts of waste, thus failing to provide ecofriendly and sustainable solutions for water purification. Over the years, novel additive manufacturing technology, also known as three-dimensional (3D) printing, has propelled remarkable innovation in different disciplines owing to its capability to fabricate customized geometric objects rapidly and cost-effectively with minimal byproducts and hence undoubtedly emerged as a promising alternative for wastewater treatment. Especially in membrane technology, 3D printing enables the designing of ultrathin membranes and membrane modules layer-by-layer with different morphologies, complex hierarchical structures, and a wide variety of materials otherwise unmet using conventional fabrication strategies. Extensive research has been dedicated to preparing membrane spacers with excellent surface properties, potentially improving the membrane filtration performance for water remediation. The revolutionary developments in membrane module fabrication have driven the utilization of 3D printing approaches toward manufacturing advanced membrane components, including biocarriers, sorbents, catalysts, and even whole membranes. This perspective highlights recent advances and essential outcomes in 3D printing technologies for wastewater treatment. First, different 3D printing techniques, such as material extrusion, selective laser sintering (SLS), and vat photopolymerization, emphasizing membrane fabrication, are briefly discussed. Importantly, in this Perspective, we focus on the unique 3D-printed membrane modules, namely, feed spacers, biocarriers, sorbents, and so on. The unparalleled advantages of 3D printed membrane components in surface area, geometry, and thickness and their influence on antifouling, removal efficiency, and overall membrane performance are underlined. Moreover, the salient applications of 3D printing technologies for water desalination, oil-water separation, heavy metal and organic pollutant removal, and nuclear decontamination are also outlined. This Perspective summarizes the recent works, current limitations, and future outlook of 3D-printed membrane technologies for wastewater treatment.

Suitability of Mycelium-Reinforced Nanofiber Mats for Filtration of Different Dyes

Electrospun nanofiber mats have a high specific surface area and very small pores which can be tailored by the spinning process. They are thus highly suitable as filters for small particles and molecules, such as organic dyes. On the other hand, they are usually very thin and thus have low mechanical properties. As a potential reinforcement, mycelium of Pleurotus ostreatus was grown on poly(acrylonitrile) nanofiber mats and thermally solidified after fully covering the nanofiber mats. This study investigates whether the filtration efficiency of the nanofiber mats is altered by the mycelium growing through it and whether the mechanical properties of the nanofibrous filters can be improved in this way. The study shows fast and reliable growth of the mycelium on the nanofiber mats and high filtration efficiency for astra blue and chlorophyll, while indigo carmine showed only very low filtration efficiency of up to 20%. For chlorophyll and safranin, membranes with mycelium showed higher filtration than pure nanofiber mats. In diffusion cell tests, especially astra blue was strongly adsorbed on the membranes with mycelium.

Emerging Strategies for the Biofabrication of Multilayer Composite Amniotic Membranes for Biomedical Applications

The amniotic membrane (AM) is the innermost part of the fetal placenta, which surrounds and protects the fetus. Due to its structural components (stem cells, growth factors, and proteins), AMs display unique biological properties and are a widely available and cost-effective tissue. As a result, AMs have been used for a century as a natural biocompatible dressing for healing corneal and skin wounds. To further increase its properties and expand its applications, advanced hybrid materials based on AMs have recently been developed. One existing approach is to combine the AM with a secondary material to create composite membranes. This review highlights the increasing development of new multilayer composite-based AMs in recent years and focuses on the benefits of additive manufacturing technologies and electrospinning, the most commonly used strategy, in expanding their use for tissue engineering and clinical applications. The use of AMs and multilayer composite-based AMs in the context of nerve regeneration is particularly emphasized and other tissue engineering applications are also discussed. This review highlights that these electrospun multilayered composite membranes were mainly created using decellularized or de-epithelialized AMs, with both synthetic and natural polymers used as secondary materials. Finally, some suggestions are provided to further enhance the biological and mechanical properties of these composite membranes.

Homogeneity of Needleless Electrospun Nanofiber Mats

Nanofiber mats can be electrospun by different techniques, usually subdivided into needle-based and needleless. The latter allow for producing large-area nanofiber mats, e.g., with a width of 50 cm and lengths of several meters, if electrospinning proceeds for several hours, depending on the required thickness. Even spinning smaller samples, however, raises the question of homogeneity, especially if defined mechanical properties or a defined thickness is required, e.g., for filtration purposes. Very often, only the inner parts of such electrospun nanofiber mats are used to avoid too high variation of the nanofiber mat thickness. For this study, we used wire-based electrospinning to prepare nanofiber mats with slightly varying spinning parameters. We report investigations of the thickness and mass per unit area, measured on different positions of needleless electrospun nanofiber mats. Martindale abrasion tests on different positions are added as a measure of the mechanical properties. All nanofiber mats show unexpectedly strong variations of thickness, mass per unit area, and porosity, as calculated from the apparent density of the membranes. The thickness especially varied by nearly one order of magnitude within one sample, while the apparent density, as the most uniform parameter, still showed variations by more than a factor of two within one sample. This shows that even for apparently highly homogeneous areas of such nanofiber mats, variations cannot be neglected for all potential applications.

Electrospun Magnetic Nanofiber Mats for Magnetic Hyperthermia in Cancer Treatment Applications-Technology, Mechanism, and Materials

The number of cancer patients is rapidly increasing worldwide. Among the leading causes of human death, cancer can be regarded as one of the major threats to humans. Although many new cancer treatment procedures such as chemotherapy, radiotherapy, and surgical methods are nowadays being developed and used for testing purposes, results show limited efficiency and high toxicity, even if they have the potential to damage cancer cells in the process. In contrast, magnetic hyperthermia is a field that originated from the use of magnetic nanomaterials, which, due to their magnetic properties and other characteristics, are used in many clinical trials as one of the solutions for cancer treatment. Magnetic nanomaterials can increase the temperature of nanoparticles located in tumor tissue by applying an alternating magnetic field. A very simple, inexpensive, and environmentally friendly method is the fabrication of various types of functional nanostructures by adding magnetic additives to the spinning solution in the electrospinning process, which can overcome the limitations of this challenging treatment process. Here, we review recently developed electrospun magnetic nanofiber mats and magnetic nanomaterials that support magnetic hyperthermia therapy, targeted drug delivery, diagnostic and therapeutic tools, and techniques for cancer treatment.

Electrospinning of Biomedical Nanofibers/Nanomembranes: Effects of Process Parameters

Nanotechnology has attracted great attention from researchers in modern science because nanomaterials have innovative and superior physical, chemical, and biological properties, and they can be altered and modified accordingly. As particles get smaller, their surface area increases compared to their volume. Electrospinning is one of the advanced techniques to produce ultrathin nanofibers and membranes, and it is one of the best ways to create continuous nanomaterials with variable biological, chemical, and physical properties. The produced fibers can be utilized in various domains such as wound dressing, drug release, enzyme immobilization, etc. This review examines the biomedical nanofibers/membranes produced by electrospinning techniques to investigate the effects of process parameters (e.g., solution characteristics, applied voltage, and ambient conditions) on nanofiber characteristics (physical, chemical, and mechanical properties). The solution parameters like (i) optimum concentration, (ii) higher molecular weight, and (iii) higher conductivity produce uniform nanofibers, smoother nanofibers, and a smaller and more uniform fiber diameter, respectively. In addition, process parameters such as (i) higher voltage and (ii) slower flow rate produce more polymer ejection from the nozzle and enhance the smoother fiber production, respectively. The optimum tip-to-collector distance is considered to be 13-15 cm. The ambient conditions such as (i) higher humidity and (ii) higher temperature produce thicker and thinner nanofibers, respectively. The controlled parameters through optimization process determine the size and quality of the fibers. The effects of each parameter are discussed in this review. The applications of nanofibers are also discussed.

Analysis of Metrological Quality and Mechanical Properties of Models Manufactured with Photo-Curing PolyJet Matrix Technology for Medical Applications

This paper presents the metrological quality and mechanical properties of models in the form of hook holders manufactured from MED610 polymer material using PolyJet Matrix (PJM) technology. Measurements in the dimensional and shape analysis were made using the optical method with a microscope. The mechanical test was estimated by static tensile testing of the fabricated parts. A comprehensive approach to both the analysis of test results based on standardized samples and real hook models makes the presented results of great scientific and engineering value and creates the possibility of practical use in the medical industry, which has not been so comprehensively presented in the currently published research papers. Analyzing the results of measurements of the geometrical characteristics of the elements, it can be concluded that the PolyJet Matrix 3D printing technology has demonstrated a high level of precision in manufacturing the prototype parts. The static tensile test of samples, taking into account the printing directions, showed a high anisotropy of mechanical properties. The results of both strength and simulation tests indicate that it is necessary to assume a relatively high safety factor, the value of which depends on the direction of printing, which, in the case of such a responsible medical application, is very important.

Comparative Analysis of Polymer Composites Produced by FFF and PJM 3D Printing and Electrospinning Technologies for Possible Filter Applications

Three-dimensional printing technologies are mainly used to build objects with complex shapes and geometry, largely prototypes, and thanks to the possibility of building very thin layers of material with small pores, electrospinning technology allows for the creation of structures with filtration properties, in particular very small particles. The combination of these technologies creates new possibilities for building complex-shape composites that have not been comprehensively tested so far. The article describes the results of research on composites manufactured by combining samples prepared with two 3D printing technologies, Fused Filament Fabrication (FFF) and Photo-Curing of Liquid Polymer Resins (PJM) in combination with electrospinning (ES) technology. The surface morphology of composites manufactured from biocompatible materials was investigated using confocal laser scanning microscopy (CLSM) and contact angle measurements, and chemical composition analysis was studied using Fourier transform infrared spectroscopy (FTIR). This approach to creating composites appears to be an alternative to developing research for filtration applications. The article presents basic research illustrating the quality of composites produced by combining two unconventional technologies: 3D printing and electrospinning (ES). The analysis of the research results showed clear differences in the structure of composites produced with the use of various 3D printing technologies. The CLSM analysis showed a much better orientation of the fibers in the MED610 + PAN/gelatin composite, and the measurement of the contact angle and its indirect interpretation also for this composite allows for the conclusion that it will be characterized by a higher value of adhesion force. Moreover, such composites could be used in the future for the construction of filtering devices and in medical applications.

Characterization and Filtration Efficiency of Sustainable PLA Fibers Obtained via a Hybrid 3D-Printed/Electrospinning Technique

The enormous world demand for personal protective equipment to face the current SARS-CoV-2 epidemic has revealed two main weaknesses. On one hand, centralized production led to an initial shortage of respirators; on the other hand, the world demand for single-use equipment has had a direct and inevitable effect on the environment. Polylactide (PLA) is a biodegradable, biocompatible, and renewable thermoplastic polyester, mainly derived from corn starch. Electrospinning is an established and reproducible method to obtain nano- and microfibrous materials with a simple apparatus, characterized by high air filtration efficiencies. In the present work, we designed and optimized an open-source electrospinning setup, easily realizable with a 3D printer and using components widely available, for the delocalized production of an efficient and sustainable particulate matter filter. Filters were realized on 3D-printed PLA support, on which PLA fibers were subsequently electrospun. NaCl aerosol filtration tests exhibited an efficiency greater than 95% for aerosol having an equivalent diameter greater than 0.3 μm and a fiber diameter comparable to the commercially available FFP2 melt-blown face mask. The particulate entrapped by the filters when operating in real environments (indoors, outdoors, and working scenario) was also investigated, as well as the amount of heavy metals potentially released into the environment after filtration activity.

Combining Materials Obtained by 3D-Printing and Electrospinning from Commercial Polylactide Filament to Produce Biocompatible Composites

The design of scaffolds to reach similar three-dimensional structures mimicking the natural and fibrous environment of some cells is a challenge for tissue engineering, and 3D-printing and electrospinning highlights from other techniques in the production of scaffolds. The former is a well-known additive manufacturing technique devoted to the production of custom-made structures with mechanical properties similar to tissues and bones found in the human body, but lacks the resolution to produce small and interconnected structures. The latter is a well-studied technique to produce materials possessing a fibrillar structure, having the advantage of producing materials with tuned composition compared with a 3D-print. Taking the advantage that commercial 3D-printers work with polylactide (PLA) based filaments, a biocompatible and biodegradable polymer, in this work we produce PLA-based composites by blending materials obtained by 3D-printing and electrospinning. Porous PLA fibers have been obtained by the electrospinning of recovered PLA from 3D-printer filaments, tuning the mechanical properties by blending PLA with small amounts of polyethylene glycol and hydroxyapatite. A composite has been obtained by blending two layers of 3D-printed pieces with a central mat of PLA fibers. The composite presented a reduced storage modulus as compared with a single 3D-print piece and possessing similar mechanical properties to bone tissues. Furthermore, the biocompatibility of the composites is assessed by a simulated body fluid assay and by culturing composites with 3T3 fibroblasts. We observed that all these composites induce the growing and attaching of fibroblast over the surface of a 3D-printed layer and in the fibrous layer, showing the potential of commercial 3D-printers and filaments to produce scaffolds to be used in bone tissue engineering.

Morphology of Models Manufactured by SLM Technology and the Ti6Al4V Titanium Alloy Designed for Medical Applications

This paper presents the results of an experimental study to evaluate the possibility of using SLM additive technology to produce structures with specific surface morphological features. Qualitative and quantitative tests were conducted on samples fabricated by 3D printing from titanium (Ti6Al4V)-powder-based material and analysed in direct relation to the possibility of their use in medicine for the construction of femoral stem and models with a specific degree of porosity predicted by process-control in the self-decision-making 3D printing machine. This paper presents the results of the study, limitations of the method, recommendations that should be used in the design of finished products, and design proposals to support the fabrication process of 3D printers. Furthermore, the study contains an evaluation of how the printing direction affects the formation of certain structures on the printed surface. The research can be used in the development of 3D printing standardization, particularly in the consideration of process control and surface control.

Optimization of the Projection Microstereolithography Process for a Photocurable Biomass-Based Resin

Biomass materials, an important source of chemical feedstocks, could replace fossil fuels as a resource in the future. The chemical feedstocks from biomass materials are used in many medical and pharmaceutical products and in fuels, chemicals, and functional materials. Biomass materials are expected to be used in biomedical engineering fields, especially due to their low biotoxicity. By the way, most of the demand for bio-application fields is an application targeted for customized production, so a high formability is required for production. Research on three-dimensional (3D) printing technology capable of satisfying these requirements has been ongoing. Manufacturing additives need to be investigated to use biomass materials as a resin or bioink safely for 3D printing, which is a technique widely used in biomedical engineering fields. In this study, a projection microstereolithography (PμSL) system, a 3D printing technique, was made that uses a biomass-based resin. Biomass materials are designed to be photocurable for use in the PμSL process. Various PμSL process parameters were investigated using the biomass-based resin to determine the optimum fabrication conditions for 3D structures. This study demonstrated that a biomass-based resin can be used in the PμSL process. We provide a method for its application in various biomedical engineering fields.

Optical elements from 3D printed polymers

3D printing belongs to the emerging technologies of our time. Describing diverse specific techniques, 3D printing enables rapid production of individual objects and creating shapes that would not be produced with other techniques. One of the drawbacks of typical 3D printing processes, however, is the layered structure of the created parts. This is especially problematic in the production of optical elements, which in most cases necessitate highly even surfaces. To meet this challenge, advanced 3D printing techniques as well as other sophisticated solutions can be applied. Here, we give an overview of 3D printed optical elements, such as lenses, mirrors, and waveguides, with a focus on freeform optics and other elements for which 3D printing is especially well suited.

Viscoelastic Properties of Cell Structures Manufactured Using a Photo-Curable Additive Technology-PJM

This research paper reviews the test results involving viscoelastic properties of cellular structure models made with the PolyJet Matrix-PJM additive technology. The designed test specimens were of complex cellular structure and made of three various photo-curable polymer resin types. Materials were selected taking into account the so-called "soft" and "tough" material groups. Compressive stress relaxation tests were conducted in accordance with the recommendations of standard ISO 3384, and the impact of the geometric structure shape and material selection on viscoelastic properties, as well as the most favorable geometric variants of the tested cellular structure models were determined. Mathematica and Origin software was used to conduct a statistical analysis of the test results and determine five-parameter functions approximating relaxation curves. The most favorable rheological was adopted and its mean parameters determined, which enables to match both printed model materials and their geometry in the future, to make a component with a specific rheological response. Furthermore, the test results indicated that there was a possibility of modelling cellular structures within the PJM technology, using support material as well.

Application of Electrospun Nanofibers for Fabrication of Versatile and Highly Efficient Electrochemical Devices: A Review

Electrochemical devices convert chemical reactions into electrical energy or, vice versa, electricity into a chemical reaction. While batteries, fuel cells, supercapacitors, solar cells, and sensors belong to the galvanic cells based on the first reaction, electrolytic cells are based on the reversed process and used to decompose chemical compounds by electrolysis. Especially fuel cells, using an electrochemical reaction of hydrogen with an oxidizing agent to produce electricity, and electrolytic cells, e.g., used to split water into hydrogen and oxygen, are of high interest in the ongoing search for production and storage of renewable energies. This review sheds light on recent developments in the area of electrospun electrochemical devices, new materials, techniques, and applications. Starting with a brief introduction into electrospinning, recent research dealing with electrolytic cells, batteries, fuel cells, supercapacitors, electrochemical solar cells, and electrochemical sensors is presented. The paper concentrates on the advantages of electrospun nanofiber mats for these applications which are mostly based on their high specific surface area and the possibility to tailor morphology and material properties during the spinning and post-treatment processes. It is shown that several research areas dealing with electrospun parts of electrochemical devices have already reached a broad state-of-the-art, while other research areas have large space for future investigations.

Multiscale Analysis of Surface Texture Quality of Models Manufactured by Laser Powder-Bed Fusion Technology and Machining from 316L Steel

The paper presents the results of tests aimed at evaluating the surface textures of samples manufactured from material based on 316L stainless steel. The analysis of the surface topography was conducted based on the classical approach in accordance with the current standard and with the use of multiscale methods; i.e., wavelet transformation and geometric via curvature. Selective laser melting 3D printing technology was used to produce samples for surface testing. Furthermore, additional assessment of surfaces created as result of milling was conducted. Statistical research demonstrated a differentiation in the distribution of particular morphological features in certain ranges of the analyzed scales.

Electrospun Nanofiber Mats for Filtering Applications-Technology, Structure and Materials

Air pollution is one of the biggest health and environmental problems in the world and a huge threat to human health on a global scale. Due to the great impact of respiratory viral infections, chronic obstructive pulmonary disease, lung cancer, asthma, bronchitis, emphysema, lung disease, and heart disease, respiratory allergies are increasing significantly every year. Because of the special properties of electrospun nanofiber mats, e.g., large surface-to-volume ratio and low basis weight, uniform size, and nanoporous structure, nanofiber mats are the preferred choice for use in large-scale air filtration applications. In this review, we summarize the significant studies on electrospun nanofiber mats for filtration applications, present the electrospinning technology, show the structure and mechanism of air filtration. In addition, an overview of current air filtration materials derived from bio- and synthetic polymers and blends is provided. Apart from this, the use of biopolymers in filtration applications is still relatively new and this field is still under-researched. The application areas of air filtration materials are discussed here and future prospects are summarized in conclusion. In order to develop new effective filtration materials, it is necessary to understand the interaction between technology, materials, and filtration mechanisms, and this study was intended to contribute to this effort.

3D Printable Electrically Conductive Hydrogel Scaffolds for Biomedical Applications: A Review

Electrically conductive hydrogels (ECHs), an emerging class of biomaterials, have garnered tremendous attention due to their potential for a wide variety of biomedical applications, from tissue-engineered scaffolds to smart bioelectronics. Along with the development of new hydrogel systems, 3D printing of such ECHs is one of the most advanced approaches towards rapid fabrication of future biomedical implants and devices with versatile designs and tuneable functionalities. In this review, an overview of the state-of-the-art 3D printed ECHs comprising conductive polymers (polythiophene, polyaniline and polypyrrole) and/or conductive fillers (graphene, MXenes and liquid metals) is provided, with an insight into mechanisms of electrical conductivity and design considerations for tuneable physiochemical properties and biocompatibility. Recent advances in the formulation of 3D printable bioinks and their practical applications are discussed; current challenges and limitations of 3D printing of ECHs are identified; new 3D printing-based hybrid methods for selective deposition and fabrication of controlled nanostructures are highlighted; and finally, future directions are proposed.

Dynamic Mechanical Behavior of Hierarchical Resin Honeycomb by 3D Printing

In this paper, surface projection micron stereo-lithography technology (PμSL) by 3D printing was used to prepare two resin honeycomb materials with different levels, and the mechanical behavior of these materials was studied. The quasi-static compression experiment and the dynamic compression experiment were carried out on the samples using the in situ micro-compression testing machine and the Split Hopkinson bar (SHPB) experimental equipment. The stress–strain curves of these materials at different strain rates were obtained, and the energy absorption characteristic of materials with two different levels were analyzed. This article reveals that the collapse strength and energy absorption properties of the materials are related to the hierarchical level of honeycomb. Multi-level hierarchical honeycomb (MHH) has higher collapse strength and better energy absorption properties than single-level hierarchical honeycomb (SHH). It turned out that increasing the hierarchical level of honeycomb could improve the mechanical properties of the materials. In the future development of products, the mechanical properties of hierarchical material by 3D printing can be further optimized through changing the level of the fractal structure.

Tensile Strength Analysis of Thin-Walled Polymer Glass Fiber Reinforced Samples Manufactured by 3D Printing Technology

The paper describes the mechanical properties, determined on the basis of a tensile strength test of a composite material based on glass-fiber reinforced polyamide and obtained by Selective Laser Sintering-SLS. The material used is PA 3200 GF. Thin walled samples with non-standard nominal thicknesses of 1, 1.4 and 1.8 mm, manufactured in three printing directions X, Y and Z, were used. The description included the impact of printing direction on the geometry of the obtained samples and tensile strength as well as the dependency of tensile strength on the sample thickness. The results can be useful for design engineers and process engineers designing thin-walled components produced with SLS. Thin samples were obtained with a considerable deviation spread of the actual dimension from the nominal one. It was found that the tensile strength of thin samples is much lower than those of standard cross-sections, which should be taken into account in the design of thin-walled elements.

Waviness of Freeform Surface Characterizations from Austenitic Stainless Steel (316L) Manufactured by 3D Printing-Selective Laser Melting (SLM) Technology

The paper presents the results of tests of surface waviness of samples made in the powder bed fusion technology. The models were built using 316L steel-based powder with high corrosion resistance. The samples were placed on the construction platform at three different angles (0°, 45°, 90°) in XZ plane. Then, using an optical profilometer, the parameters of the geometric structure of the surface of the primary profile and the separated waviness component were measured. Analyzing the results of the test, it can be stated that the orientation of model arrangement has an impact on the quality of the technological surface texture, what has significance impact on wear processes and mechanical properties.

Electron-Beam Irradiation of the PLLA/CMS/β-TCP Composite Nanofibers Obtained by Electrospinning

Nanofibrous materials produced by electrospinning processes have potential advantages in tissue engineering because of their biocompatibility, biodegradability, biomimetic architecture, and excellent mechanical properties. The aim of the current work is to study the influence of the electron beam on the poly L-lactide acid/ carboxy-methyl starch/β-tricalcium phosphate (PLLA/CMS/β-TCP) composite nanofibers for potential applications as bone-tissue scaffolds. The composite nanofibers were prepared by electrospinning in the combination of 5% v/v carboxy-methyl starch (CMS) and 0.25 wt% of β-TCP with the PLLA as a matrix component. The composites nanofibers were exposed under 5, 30, and 100 kGy of irradiation dose. The electron-beam irradiation showed no morphological damage to the fibers, and slight reduction in the water-contact angle and mechanical strength at the higher-irradiation doses. The chain scission was found to be a dominant effect; the higher doses of electron-beam irradiation thus increased the in vitro degradation rate of the composite nanofibers. The chemical interaction due to irradiation was indicated by the Fourier transform infrared (FTIR) spectrum and thermal behavior was investigated by a differential scanning calorimeter (DSC). The results showed that the electron-beam-induced poly L-lactide acid/carboxy-methyl starch/β-tricalcium phosphate (PLLA/CMS/β-TCP) composite nanofibers may have great potential for bone-tissue engineering.

Enhancement of Gas Barrier Properties of Graphene Oxide/Poly (Lactic Acid) Films Using a Solvent-free Method

Graphene oxide(GO)/polylactic acid (PLA) nanocomposite, prepared using a solvent-free melt mixing processing, is investigated as a potential oxygen barrier packaging film in this work. In order to disperse GO homogeneously in PLA matrix, hydrophobic silane coupling agent, i.e., γ-(2,3-epoxypropoxy)propyltrimethoxysilane (KH560), is used to modify the graphene oxide sheets. The modified GO is able to be well bonded to the PLA due to the formation of covalent bonds between the epoxy groups of KH560 and the carboxyl and hydroxyl terminal groups of PLA. Furthermore, the thermal stability of GO is enhanced due to the long alkyl side chain of KH560, which could also increase the crystallinity of PLA. As a result, the crystallinity of PLA is significantly improved because of the linear KH560 chains, which can act as nucleating agents to improve the crystallization. The KH560-GO helps to reduce the O₂ permeability of KH560-GO/PLA composite films via a dual-action mechanism: (1) providing physical barrier due to their native barrier properties, and (2) by resulting in higher degree of crystallinity. The as-prepared KH560-GO0.75/PLA is able to exhibit ca. 33% and ca. 13% decrease in the P_O2 than the neat PLA and GO0.75/PLA film, respectively. Finally, the mechanical properties and impact fractured surfaces indicate that the increase in the tensile strength and elongation at break value of KH560-GO/PLA are due to the strong interfacial adhesion and the strong bonding between the epoxy group of KH560-GO and hydroxyl and carboxyl acid terminal groups of PLA matrix.

3D Printed and Electrospun, Transparent, Hierarchical Polylactic Acid Mask Nanoporous Filter

Face masks are becoming one of the most useful personal protective equipment with the outbreak of the coronavirus (CoV) pandemic. The entire world is experiencing shortage of disposable masks and melt-blown non-woven fabrics, which is the raw material of the mask filter. Recyclability of the discarded mask is also becoming a big challenge for the environment. Here, we introduce a facile method based on electrospinning and three-dimensional printing to make changeable and biodegradable mask filters. We printed polylactic acid (PLA) polymer struts on a PLA nanofiber web to fabricate a nanoporous filter with a hierarchical structure and transparent look. The transparent look overcomes the threatening appearance of the masks that can be a feasible way of reducing the social trauma caused by the current CoV disease-19 pandemic. In this study, we investigated the effects of nozzle temperature on the optical, mechanical, and morphological and filtration properties of the nanoporous filter.

The Influence of Printing Orientation on Surface Texture Parameters in Powder Bed Fusion Technology with 316L Steel

Laser technologies for fast prototyping using metal powder-based materials allow for faster production of prototype constructions actually used in the tooling industry. This paper presents the results of measurements on the surface texture of flat samples and the surface texture of a prototype of a reduced-mass lathe chuck, made with the additive technology—powder bed fusion. The paper presents an analysis of the impact of samples’ orientation on the building platform on the surface geometrical texture parameters (two-dimensional roughness profile parameters (Ra, Rz, Rv, and so on) and spatial parameters (Sa, Sz, and so on). The research results showed that the printing orientation has a very large impact on the quality of the surface texture and that it is possible to set digital models on the building platform (parallel—0° to the building platform plane), allowing for manufacturing models with low roughness parameters. This investigation is especially important for the design and 3D printing of microelectromechanical systems (MEMS) models, where surface texture quality and printable resolution are still a large problem.

Morphology and Mechanical Properties of 3D Printed Wood Fiber/Polylactic Acid Composite Parts Using Fused Deposition Modeling (FDM): The Effects of Printing Speed

In this study, a wood fiber/polylactic acid composite (WPC) filament was used as feedstock to print the WPC part by means of fused deposition modeling (FDM). The morphology and mechanical properties of WPC parts printed at different speeds (30, 50, and 70 mm/s) were determined. The results show that the density of the printed WPC part increased as the printing speed decreased, while its surface color became darker than that of parts printed at a high speed. The printing time decreased with an increasing printing speed; however, there was a small difference in the time saving percentage without regard to the dimensions of the printed WPC part at a given printing speed. Additionally, the tensile and flexural properties of the printed WPC part were not significantly influenced by the printing speed, whereas the compressive strength and modulus of the FDM-printed part significantly decreased by 34.3% and 14.6%, respectively, when the printing speed was increased from 30 to 70 mm/s. Furthermore, scanning electronic microscopy (SEM) illustrated that the FDM process at a high printing speed produced an uneven surface of the part with a narrower width of printed layers, and pull-outs of wood fibers were more often observed on the fracture surface of the tensile sample. These results show that FDM manufacturing at different printing speeds has a substantial effect on the surface color, surface roughness, density, and compressive properties of the FDM-printed WPC part.

Stress Relaxation and Creep of a Polymer-Aluminum Composite Produced through Selective Laser Sintering

This article discusses the rheological properties (stress relaxation and creep) of polymer-aluminum composite specimens fabricated through the selective laser sintering (SLS) from a commercially available powder called Alumide. The rheological data predicted using the Maxwell–Wiechert and the Kelvin–Voigt models for stress relaxation and creep, respectively, were in agreement with the experimental results. The elastic moduli and dynamic viscosities were determined with high accuracy for both models. The findings of this study can be useful to designers and users of SLS prints made from the material tested.