Computational nodal displacement analysis of acetabulum fossa for injection molded cemented polyethylene acetabular liner

The acetabular liner (AL) is one of the key components that determine the functionality and durability of the total hip joint replacement (THR) device. The performance of Ultra high molecular weight polyethylene (UHMWPE)-based AL depends critically on the manufacturing route and its properties, which are evaluated pre-clinically using a host of experimental and computational analyses. The conventional manufacturing of an AL involves multiple stages, including extrusion/compression molding followed by machining, which is time/cost intensive and leads to material loss. In such a scenario, injection molding is a promising alternative, yet its feasbility remains unexplored for the manufacturing of AL for THA applications. Against this backdrop, the two-fold objectives of this work are to report our recent efforts to establish the efficacy of the injection molding of new generation UHMWPE biomaterial; HU (60 wt% HDPE- 40 wt% UHMWPE blend) for manufacturing AL prototype and to present the key biomechanical response analysis of this prototype, in silico. A range of manufacturing relevant material properties, as well as customized mold design to manufacture HU-based AL with external design features, are discussed. Such guidelines are particularly relevant to mold polymeric parts with a higher thickness (>8 mm). As part of the pre-clinical validation of AL with new design features, a less explored in silico approach to assess biomechanical micro-strain in the acetabulum fossa is presented, and the results are analysed in accordance with the mechanostat theory. The outcomes revealed that for a 100 kg subject weight, average micro-strain in the remodelling region was 1132, while it was determined as 723 for a 55 kg subject weight. Such results highlight the influence of subject weight on micro-strain generation and distribution in the acetabulum fossa. The von Mises stress in AL also increased with subject weight from 17 MPa in a subject weight of 55 kg to 28 MPa in a subject weight of 100 kg. Taken together, this work demonstrates the feasibility and competence of this new generation biomaterial in terms of implant manufacturing via injection molding with a clinically desired biomechanical response.

Generative machine learning-based multi-objective process parameter optimization towards energy and quality of injection molding

The high energy intensity and rigorous quality demand of injection molding have received significant interest under the background of the soaring production of global plastic industry. As multiple parts can be produced in a multi-cavity mold during one operation cycle, the weight differences of these parts have been demonstrated to reflect their quality performance. In this regard, this study incorporated this fact and developed a generative machine learning-based multi-objective optimization model. Such model can predict the qualification of parts produced under different processing variables and further optimize processing variables of injection molding for minimal energy consumption and weight difference amongst parts in one cycle. Statistical assessment via F₁-score and R² was performed to evaluate the performance of the algorithm. In addition, to validate the effectiveness of our model, we conducted physical experiments to measure the energy profile and weight difference under varying parameter settings. Permutation-based mean square error reduction was adopted to specify the importance of parameters affecting energy consumption and quality of injection molded parts. Optimization results indicated that the processing parameters optimization could reduce ~ 8% energy consumption and ~ 2% weight difference compared with the average operation practices. Maximum speed and first-stage speed were identified as the dominating factors affecting quality performance and energy consumption, respectively. This study could contribute to the quality assurance of injection molded parts and facilitate energy efficient and sustainable plastic manufacturing.

Starch consolidation of calcium carbonate as a tool to develop lightweight fillers for LDPE-based plastics

Calcium carbonate (CaCO3) is used as a filler to improve the stiffness and processability of plastics at low cost. However, its high density limits the quantity to be used. In this work, the feasibility of using starch consolidation of eggshells-derived CaCO3 (ES) to develop lightweight fillers for low density polyethylene (LDPE)-based materials was studied. Starch, recovered from potato by-products, was combined with ES, gelatinized, dried, and milled as a fine powder. The obtained ES/starch-based particles were then compounded with LDPE and their influence on chromatic, mechanical, morphological, and density properties of mold injected LDPE-based materials was studied. Commercially available CaCO3 (COM) was used as control. ES/starch particles were 18 times less dense than the commercially available CaCO3 (2.62 g cm-3). When incorporated into LDPE-based formulations, ES/starch originated brownish materials with lower density (1.18 g cm-3) and higher stiffness (542 MPa of Young's modulus) than those produced with the COM sample (1.33 g cm-3 of density; 221 MPa of Young's modulus). Therefore, starch consolidation of ES revealed to be a promising approach to develop lightweight fillers able to provide stiffness and color to LDPE-based plastics, while valorizing biomolecules-rich by-products.

Poly(2-alkyl-2-oxazoline)s: A polymer platform to sustain the release from tablets with a high drug loading

Sustaining the release of highly dosed APIs from a matrix tablet is challenging. To address this challenge, this study evaluated the performance of thermoplastic poly (2-alkyl-2-oxazoline)s (PAOx) as matrix excipient to produce sustained-release tablets via three processing routes: (a) hot-melt extrusion (HME) combined with injection molding (IM), (b) HME combined with milling and compression and (c) direct compression (DC). Different PAOx (co-)polymers and polymer mixtures were processed with several active pharmaceutical ingredients having different aqueous solubilities and melting temperatures (metoprolol tartrate (MPT), metformin hydrochloride (MTF) and theophylline anhydrous (THA)). Different PAOx grades were synthesized and purified by the Supramolecular Chemistry Group, and the effect of PAOx grade and processing technique on the in vitro release kinetics was evaluated. Using the hydrophobic poly (2-n-propyl-2-oxazoline) (PⁿPrOx) as a matrix excipient allowed to sustain the release of different APIs, even at a 70% (w/w) drug load. Whereas complete THA release was not achieved from the PⁿPrOx matrix over 24 ​h regardless of the processing technique, adding 7.5% w/w of the hydrophilic poly (2-ethyl-2-oxazoline) to the hydrophobic PⁿPrOx matrix significantly increased THA release, highlighting the relevance of mixing different PAOx grades. In addition, it was demonstrated that the release of THA was similar from co-polymer and polymer mixtures with the same polymer ratios. On the other hand, as the release of MTF from a PⁿPrOx matrix was fast, the more hydrophobic poly (2-sec-butyl-2-oxazoline) (P^secBuOx) was used to retard MTF release. In addition, a mixture between the hydrophilic PEtOx and the hydrophobic P^secBuOx allowed accurate tuning of the release of MTF formulations. Finally, it was demonstrated that PAOx also showed a high ability to tune the in vivo release. IM tablets containing 70% MTF and 30% P^secBuOx showed a lower in vivo bioavailability compared to IM tablets containing a low PEtOx concentration (7.5%, w/w) in combination with P^secBuOx (22.5%, w/w). Importantly, the in vivo MTF blood level from the sustained release tablets correlated well with the in vitro release profiles. In general, this work demonstrates that PAOx polymers offer a versatile formulation platform to adjust the release rate of different APIs, enabling sustained release from tablets with up to 70% w/w drug loading.

Polyamide (PA) 66 molding defect studied with optical coherence tomography (OCT) and near-infrared (NIR) spectroscopy

An optical coherence tomography (OCT) system combined with near-infrared spectroscopy (NIRS) was developed to carry out simultaneously the cross-sectional observation and spectral measurement of a specific area inside a polymer sample. This OCT-NIRS system consists of a fiber-optic-based spectrometer combined with an OCT system and enables non-invasive imaging up to a depth of several millimeters and the recording of the NIR spectrum in the observed area. A subsequent analysis of the collected data will provide key information revealing the way in which the microscopic structure of the polymer is affected by the chemical composition around it. A structural defect inside a molded polyamide (PA) 66 sample was examined with the OCT-NIRS system to demonstrate how this technique can be utilized to characterize chemical composition as well as the morphological features inside the sample. A specific void was detected by OCT when the PA sample was molded without any drying treatment. The NIR spectrum collected around the void area of the undried PA was then compared with that of vacuum-dried PA by two-trace two-dimensional (2T2D) correlation analysis to identify a subtle but pertinent difference in the spectral features. The appearance of several correlation peaks in the 2T2D asynchronous correlation spectrum revealed that the OH group represented by the NIR band at 1446 nm is found in relative abundance around the void, which clearly reveals that the development of the void in the molded PA results from inadequate sample pretreatment.

Novel data-driven two-dimensional Q-learning for optimal tracking control of batch process with unknown dynamics

In view that the previous control methods usually rely too much on the models of batch process and have difficulty in a practical batch process with unknown dynamics, a novel data-driven two-dimensional (2D) off-policy Q-learning approach for optimal tracking control (OTC) is proposed to make the batch process obtain a model-free control law. Firstly, an extended state space equation composing of the state and output error is established for ensuring tracking performance of the designed controller. Secondly, the behavior policy of generating data and the target policy of optimization as well as learning is introduced based on this extended system. Then, the Bellman equation independent of model parameters is given via analyzing the relation between 2D value function and 2D Q-function. The measured data along the batch and time directions of batch process are just taken to carry out the policy iteration, which can figure out the optimal control problem despite lacking systematic dynamic information. The unbiasedness and convergence of the designed 2D off-policy Q-learning algorithm are proved. Finally, a simulation case for injection molding process manifests that control effect and tracking effect gradually become better with the increasing number of batches.

Poly(lactic acid)/thermoplastic cassava starch blends filled with duckweed biomass

Duckweed (DW) is a highly small, free-floating aquatic plant. It grows and reproduces rapidly, comprises mainly protein and carbohydrate, and has substantial potential as a feedstock to produce bioplastics due to its renewability and having very little impact on the food chain. The aim of this work was to analyze the effect of DW biomass on the characteristics and properties of bio-based and biodegradable plastics based on a poly(lactic acid)/thermoplastic cassava starch (PLA/TPS) blend. Various amounts of DW biomass were compounded with PLA and TPS in a twin-screw extruder and then converted into dumbbell-shaped specimens using an injection molding machine. The obtained PLA/TPS blends filled with DW biomass exhibited a lower melt flow ability, higher moisture content, and increased surface hydrophilicity than the neat PLA/TPS blend. Incorporation of DW with low concentrations of 2.3 and 4.6 wt% increased the tensile strength, Young's modulus, and hardness of the PLA/TPS blend. Moisture and glycerol from DW and TPS played important roles in reducing the T_g, T_cc, T_m, and T_d of PLA in the blends. The current work demonstrated that DW could be used as a biofiller for PLA/TPS blends, and the resulting PLA/TPS blends filled with DW biomass have potential in manufacturing injection-molded articles for sustainable, biodegradable, and short-term use.

Thermoplastic Microfluidics

Thermoplastic polymers are besides glass the material of choice for the industrialization of microfluidic and organ-on-chip applications. In most cases, however, such devices are developed on the basis standard lithographic clean room technologies and subsequent casting into PDMS. This results in comparably fast progress in the development of functional designs but important aspects with respect to later industrialization are thereby largely neglected. For that reason, it is advisable to switch at a rather early stage of development from PDMS to a thermoplastic polymer such as, for instance, cyclo-olefin (co)polymer (COC, COP). By making this step, additional challenges related to the anticipated manufacturing process can be identified, which is particularly important when aiming at industrialization. We present herein a standard process sequence for mastering of microfluidic devices by two-photon polymerization and final transfer into COC films by hot embossing. In addition, we describe the laser micromanufacturing of polymeric mold inserts and subsequent prototype injection molding of small series of COP samples.

Recent progress in minimizing the warpage and shrinkage deformations by the optimization of process parameters in plastic injection molding: a review

The quality control of plastic products is an essential aspect of the plastic injection molding (PIM) process. However, the warpage and shrinkage deformations continue to exist because the PIM process is easily interfered with by several related or independent process parameters. Thus, great efforts have been devoted to optimizing process parameters to minimize the warpage and shrinkage deformations of products during the last decades. In this review, we begin by introducing the manufacturing process in PIM and the cause of warpage and shrinkage deformations, followed by the mechanism about how process parameters, like mold temperature, melt temperature, injection rate, injection pressure, holding pressure, holding and cooling duration, affect those defects. Then, we summarize the recent progress of the design of experiments and four advanced methods (artificial neural networks, genetic algorithm, response surface methodology, and Kriging model) on optimizing process parameters to minimize the warpage and shrinkage deformations. In the end, future perspectives of quality control in injection molding machines are discussed.

Comparison of Real and Simulated Fiber Orientations in Injection Molded Short Glass Fiber Reinforced Polyamide by X-ray Microtomography

During injection molding of short glass fiber reinforced composites, a complex structure is formed due to the fiber movement. The resulting fiber orientation can be predicted using various simulation models. However, the models are known to have inadequacies andthe influence of process and model parameters is not clearly and comprehensively described. In this study, the aforementioned model and process parameters are investigated to determine the dependencies of the individual influences on the real and simulated fiber orientation. For this purpose, specimens are injection molded at different process parameters. Representative regions of the specimens are measured using X-ray microtomography and dynamic image analysis to determine the geometric properties of the fibers as well as their orientations. Furthermore, simulations are performed with the simulation software Moldflow^® using different mesh types and densities as well as varying parameters of the MRD model to represent the real fiber orientations. The results show that different orientation areas arise in the samples, which cannot be represented with a simulation varying only one parameter. Several simulations must be carried out in order to represent flow regions occurring in the specimen as realistically as possible.

Extra-oral assessment of conventional and CAD-CAM complete denture appearance by dental professionals and CRDP wearers: A randomized survey

INTRODUCTION

Complete removable dental prostheses' (CRDPs) appearance may vary between conventional and contemporary CAD-CAM manufacturing techniques.

OBJECTIVES

The aim of this randomized survey was to analyze appreciation of CRDPs, manufactured with different techniques, by dental professionals and elder CRDP wearers.

METHODS

Four participant groups, comprised of undergraduate students (n=10), postgraduate residents (n=10), dental technicians (n=10) and elder CRDP wearers (n=10), evaluated the appearance of maxillary CRDPs manufactured by six different techniques: three conventional methods 1. flask-pack-press (FP), 2. Injection-molded (IM), 3. intrinsically colored natural gingiva finish before injection-molded (NG) and three CAD-CAM methods 4. milled base with bonded prefabricated teeth (M), 5. fully milled including milled teeth (FM) and 6. rapid-prototyped including printed teeth (P). A randomized, blinded survey included 18 pairwise comparative assessments and 12 individual judgements of the CRDPs on general appearance as well as pink and white aspects. Statistical analyses included parametric- and nonparametric tests as well as linear regression models; the level of statistical significance was set at p<.05.

RESULTS

NG was preferred by the professional groups but not by the elder CRDP wearers (p<.05). P was scored lowest by all four participant groups (p<.05). CRDP wearers' ratings were less severe and within a narrower range. The ratings of the two CAD-CAM milled CRDPs (M and FM) were ranked closer to FP and IM); the order of preference was different depending on the participant groups.

CONCLUSIONS

The findings of this study revealed marked differences in the assessment of CRDP appearances between dental professionals and older CRDP wearers.

CLINICAL SIGNIFICANCE

A shared and informed approach to decision making concerning the CRDP appearance might foster denture acceptance and treatment success.

Injection-Molded Coamorphous Tablets: Analysis of Intermolecular Interaction and Crystallization Propensity

The processing steps involved in converting from a powder to a tablet entail numerous operations in a which the coamorphous system is recrystallized and dissociated easily. This research focused on (i) a single-step preparation of a coamorphous tablet during injection molding (IM) from the bulk powder, and (ii) a mechanistic characterization of the coamorphous formulation. We selected several organic acids [citric acid, succinic acid, tartaric acid, and malic acid] in an effort to compound with basic loratadine (a poorly water-soluble drug). Loratadine-acids coamorphous tablets were produced via an IM process, and the dissolution was more enhanced than in the pure loratadine amorphous. The interaction was analyzed by FT-IR and terahertz spectroscopies. Each tablet was stored at 40 °C/75%RH, and then XRD patterns were acquired at the desired timepoints. In summary, loratadine exhibited ionic interaction with each acid, and the physical stability of the coamorphous tablet was in proportion to the loratadine-acids interaction strength. Terahertz spectra detected the molecular mobility, which plays an important role in the crystallization propensity of a coamorphous system. This understanding offers a framework for robust coamorphous tablet formulation using the IM methodology.

Polycaprolactone/polyethylene-glycol capsules made by injection molding: A drug release modeling

Polycaprolactone (PCL)/Polyethylene-glycol (PEG) capsules are prepared by injection molding with the aim of producing Colon-specific Drug Delivery Systems (CDDS). PCL, being a gastroresistant polymer, is suitable for this kind of delivery; however, the release from PCL devices is too slow. For this reason, in this paper, different percentages of PEG (10, 20 and 30 w/w %) have been added to obtain blends able to modulate the release from PCL-based capsules. The drug release rate from PCL/PEG capsules increases with the PEG percentage; using PCL/PEG 70/30 w/w capsules, the drug release is suitable for CDDS. The experimental data have been modelled, accounting for three steps: the penetration of the release medium into the capsule, the drug dissolution in the release medium, and the drug migration from the capsule to the medium. The model accurately describes the data, showing a mass transfer coefficient strongly dependent on the PEG percentage.

Rheological characterization, compression, and injection molding of hydroxyapatite-silk fibroin composites

Traditional bone fixation devices made from inert metal alloys provide structural strength for bone repair but are limited in their ability to actively promote bone healing. Although several naturally derived bioactive materials have been developed to promote ossification in bone defects, it is difficult to translate small-scale benchtop fabrication of these materials to high-output manufacturing. Standard industrial molding processes, such as injection and compression molding, have typically been limited to use with synthetic polymers since most biopolymers cannot withstand the harsh processing conditions involved in these techniques. Here we demonstrate injection and compression molding of a bioceramic composite comprised of hydroxyapatite (HA) and silk fibroin (SF) from Bombyx mori silkworm cocoons. Both the molding behavior of the HA-SF slurry and final scaffold mechanics can be controlled by modulating SF protein molecular weight, SF content, and powder-to-liquid ratio. HA-SF composites with up to 20 weight percent SF were successfully molded into stable three-dimensional structures using high pressure molding techniques. The unique durability of silk fibroin enables application of common molding techniques to fabricate composite silk-ceramic scaffolds. This work demonstrates the potential to move bone tissue engineering one step closer to large-scale manufacturing of natural protein-based resorbable bone grafts and fixation devices.

Towards a general application programming interface (API) for injection molding machines

Injection molding is a complicated process, and the final part quality depends on many machine and process parameters settings. To increase controllability of the injection molding process, acquisition of the process data is necessary. This paper describes the architecture and development of a prototype of an open application programming interface (API) for injection molding machines (IMMs), which has the potential to be used with different IMMs to log and set the necessary process parameter values. At the moment, the API includes an implementation of EMI data exchange protocol and can be used with ENGEL IMMs with CC300 and RC300 controllers. Data collection of up to 97 machine and process parameters (the number might vary depending on the type of machine at hand), obtained from sensors installed in the machine by the manufacturer is allowed. The API also includes a module for the acquisition of data from additional 3d party sensors. Industrial Raspberry Pi (RevPi) was used to perform analog-to-digital signal conversion and make sensors data accessible via the API prototype. The logging of parameters from the machine and from sensors is synchronized and the sampling frequency can be adjusted if necessary. The system can provide soft real-time communication.

Prediction of injection molding parameters for symmetric spur gear

Polymer gears pose major advantages, like noiseless operation, resistive against corrosion, low weight, ability to damp vibrations, ease of manufacturability, and ability to operate without lubrication like in printers, household appliances, etc. In order to enhance mechanical properties of gear materials, various reinforcing materials are added such as glass and carbon fibers. The orientation of these fibers and distribution are critical parameters at the microstructural level for polymer reinforced with short fibers, which defines the strength and life of gears. The geometric accuracy and precision of molded gears are improved by the injection molding technique. The fiber orientation prediction is a new and novel aspect for high performance and life, as these injection-molded gears have complex patterns of fiber orientation. This also affects material properties such as elastic modulus, strength, and gear geometrical dimensional properties shrinkage and warpage. In this present work, an attempt is made to develop 3D symmetric spur gear tooth geometry using Autodesk Fusion 360. The injection molding parameters such as fiber orientation tensor, volumetric shrinkage at ejection, weld lines, deflection, and confidence in filling are studied for modeled gear having symmetric teeth profile for unreinforced and 20%, 30%, 40%, 50%, and 60% glass fiber-reinforced nylon 6/6 (PA66) by using Autodesk Moldflow Adviser 2017. The result obtained from mold simulation tool indicates that fiber orientation tensor for varying glass fiber contents was close to unity. The volumetric shrinkage considerably reduced from unreinforced PA66 to glass-reinforced PA66.Graphical abstract.

Osseointegration of a novel injection molded 2-piece ceramic dental implant: a study in minipigs

OBJECTIVES

This study compared the osseointegrative potential of a novel injection molded zirconia dental implant (Neodent Zi ceramic implant, test) and a commercially available titanium implant (Neodent Alvim implant, control) in terms of histomorphometrically derived bone-to-implant contact (BIC), first bone-to-implant contact (fBIC), and the ratio of bone area to total area (BATA) around the implant.

MATERIALS AND METHODS

A total of 36 implants, 18 per individual test device, were implanted in a split-mouth arrangement in either side of the edentulous and fully healed mandible of 6 minipigs. Histomorphometric analysis of BIC, fBIC, and BATA were performed 8 weeks post implantation and subjected to statistical non-inferiority testing. Surface characteristics of both implant types were compared in terms of contact angle, surface topography, and elemental composition.

RESULTS

BIC, fBIC, and coronal BATA values of test and control implants were statistically comparable and non-inferior. BIC values of 77.8 ± 6.9% vs. 80.7 ± 6.9% (p = 0.095) were measured for the test and control groups. fBIC lingual values were - 238 ± 328 μm compared with - 414 ± 511 μm (p = 0.121) while buccal values were - 429 ± 648 μm and - 588 ± 550 μm (p = 0.230) for the test and control devices, respectively. BATA in the apical segment was significantly higher in the test group compared with the control group (67.2 ± 11.8% vs. 59.1 ± 11.4%) (p = 0.0103). Surface topographies of both implant types were comparable. Surface chemical analysis indicated the presence of carbonaceous adsorbates which correlated with a comparable and predominantly hydrophobic character of the implants.

CONCLUSION

The results demonstrate that the investigated zirconia implants, when compared with a commercially available titanium implant, show equivalent and non-inferior bone integration, bone formation, and alveolar bone level maintenance. This qualifies the investigated zirconia implant as a potential candidate for clinical development.

CLINICAL RELEVANCE

This study investigated the osseointegration of a novel zirconia 2-piece dental implant prototype intended for clinical development. With the aim of translating this prototype into clinical development preclinical models, procedures and materials within this study have been selected as close to clinical practice and human physiological conditions as possible.

Mass-customization of oral tablets via the combination of 3D printing and injection molding

The new frontier of medicine is the personalization of treatment to match a patient's individual needs. Fused-filament fabrication (FFF) offers a platform for the personalization of drug dosage forms, but one of its chief shortcomings compared to other tablet production methods such as dry compression and wet granulation is relatively low throughput. Conversely, injection molding (IM) is a manufacturing technique for the high-volume production of parts, but in which individual part customization is both expensive and slow requiring the modification of expensive mold tooling. Mass-customization is the manufacture of custom products that match the needs of individual consumers but which are produced at the low unit cost associated with high-volume production. We successfully integrated for the first time FFF with IM in a multi-step manufacturing process for the production of custom bilayer tablets loaded with two active pharmaceutical ingredients used in the treatment of cardiovascular disease. The FFF layer was loaded with the diuretic hydrochlorothiazide, while the IM layer was loaded with lovastatin. Infill percentage was varied for the FFF layer as a means to modify drug release. The IM injection pressure was evaluated for its effect on drug release and layer-layer adhesion. The bilayer tablets obtained offered different combinations of drug release profiles, which were governed by a combination of factors, including surface area to volume ratio; IM injection volume penetration into the FFF layer; FFF infill percentage; layer tortuosity and porosity. These different parameters could be utilized to modify the individual release of both drugs from the bilayer tablet. Thus for the first time, we have demonstrated a viable method for the mass-customization of oral tablets which could hasten the rollout of personalized medicine.

Fabrication of Plano-Concave Plastic Lens by Novel Injection Molding Using Carbide-Bonded Graphene-Coated Silica Molds

Injection molding of plastic optical lenses prevails over many other techniques in both efficiency and cost, however polymer shrinkage during cooling, high level of uneven residual stresses and refractive index variations have limited its potential use for high precision lenses fabrication. In this research, we adopted a newly-developed strong graphene network to both plain and convex fused silica mold surfaces and proposed a novel injection molding of plano-concave lenses with graphene coated fused silica molds. The unique combination of the graphene coating and fused silica substrate maximize the mechanical properties of the mold and coating materials, namely high hardness, low surface friction, and high heat preservation effect during cooling since fused silica has low thermal conductivity. This advanced injection molding process was implemented in molding of plano-concave lenses resulting in reduced polymer shrinkage. In addition, internal residual stresses, and refractive index variations were also analyzed and discussed in detail. Meanwhile, as a comparison of conventional injection mold material, aluminum mold inserts with the same shape and size were also diamond machined and then employed to mold the same plano-concave lenses. Finally, a simulation model using Moldex3D was utilized to interpret stress distributions of both graphene and aluminum molds and then validated by experiments. The comparison between graphene and aluminum molds reveals that the novel injection molding with carbide-bonded graphene coated fused silica mold inserts is capable of molding high quality optical lenses with much less shrinkage and residual stresses, but more uniform refractive index distribution.

Determination of Polyetheretherketone (PEEK) mechanical properties as a denture material

Purpose

To optimize the gypsum mold temperatures for pressed PEEK, and to estimate the impact, tensile strength and flexural properties of pressed and milled PEEK. Where appropriate, these properties were compared with those of PMMA.

Materials and Methods

Since the mold temperature could affect the properties of the injected parts, the temperature of 20 gypsum specimens was monitored using the multi-thermocouple system (n = 5). A total of 210 specimens were prepared for mechanical tests according to the ISO standard for denture base polymer (n = 10). The Izod impact, tensile strength, and flexural behavior were assessed. PEEK-OptimaNI1 (PEEK-pressed) was tested after processing via the pressing method at4 different mold temperatures. Machining PEEK-Juvora (PEEK-milled) specimens were prepared using the CAD-CAM production method. Data were analyzed via one-way ANOVA performed at a confidence level of 95% and a significant P-value of (P ≤ 0.05).

Results

In comparison to the furnace temperature more heat was required to preheat the gypsum mold up to 100, 150, 175 and 200 °C for pressing purposes. The highest impact strength was 5.7 kJ/m² for PEEK-pressed at 100 °C mold temperature and 4 kJ/m² for PEEK-milled. The latter had a higher tensile strength of 118 MPa. The best result for PEEK-pressed was 97 MPa at 200 °C mold temperature. Under a 4-point bending test, Young’s modulus of PEEK-milled was 5591 MPa, while the highest for PEEK-pressed was 4936 MPa at 200 °C mold temperature.

Conclusions

Compared to PMMA, given the superior mechanical properties of PEEK, it may become the material of choice for future use. Dentures constructed from PEEK polymer could well be routinely constructed in the near future.

Thermomechanical and in vitro biological characterization of injection-molded PLGA craniofacial plates

PURPOSE:

To evaluate the thermomechanical and in vitro biological response of poly(lactic-co-glycolic acid) (PLGA) plates for craniofacial reconstructive surgery.

METHODS:

PLGA 85/15 craniofacial plates were produced by injection molding by testing two different temperatures (i.e., 240°C, PLGA_lowT, and 280°C, PLGA_highT). The mechanical properties of the produced plates were characterized by three-point bending tests, dynamic mechanical analysis, and residual stress. Crystallinity and thermal transitions were investigated by differential scanning calorimetry. Finally, in vitro cell interaction was evaluated by using SAOS-2 as cell model. Indirect cytotoxicity tests (ISO 10-993) were performed to prove the absence of cytotoxic release. Cells were then directly seeded on the plates and their viability, morphology, and functionality (ALP) checked up to 21 days of culture.

RESULTS:

A similar performance of PLGA_lowT and PLGA_highT plates was verified in the three-point bending test and dynamic mechanical analyses. Also, the two processing temperatures did not influence the in vitro cell interaction. Cytotoxicity and ALP activity were similar for the PLGA plates and control. Cell results demonstrated that the PLGA plates supported cell attachment and proliferation. Furthermore, energy-dispersive X-ray spectroscopy revealed the presence of sub-micron particles, which were identified as inorganic mineral deposits resulting from osteoblast activity.

CONCLUSION:

The present work demonstrated that the selected processing temperatures did not affect the material performance. PLGA plates showed good mechanical properties for application in craniofacial reconstructive surgery and adequate biological properties.

Comparison of fused-filament fabrication to direct compression and injection molding in the manufacture of oral tablets

Oral tablets are a convenient form to deliver active pharmaceutical ingredients (API) and have a high level of acceptance from clinicians and patients. There is a wide range of excipients available for the fabrication of tablets thereby offering a versatile platform for the delivery of therapeutic agents to the gastrointestinal tract. However, the geometry of tablets is limited by conventional manufacturing processes. This study aimed to compare three manufacturing processes in the production of flat-faced oral tablets using the same formulation composed of a polymer blend and caffeine as a model drug: fused-filament fabrication (FFF), direct compression (DC) and injection molding (IM). Hot-melt extrusion was used to convert a powder blend into feedstock material for FFF and IM processes, while DC was performed on the powder mixture. Tablets were produced with the same dimensions and were characterized for their physical and dissolution properties. There were statistical differences in the physical properties and drug release profiles of the tablets produced by the different manufacturing processes. DC tablets displayed immediate release, IM provided sustained release over 48 h, and FFF tablets displayed both release types depending on the printing parameters. FFF continues to demonstrate high potential as a manufacturing process for the efficient production of personalized oral tablets.

On-line measurement of clamping force for injection molding machine using ultrasonic technology

The on-line measurement of clamping force is essential for injection molding equipment and process. A method for on-line measurement of clamping force using ultrasonic technology is proposed in this study. Based on the sono-elasticity theory, a new mathematical model is established to describe the relationship between ultrasonic propagation time and clamping force. A series of experiments are then performed to validate the proposed method. Findings show this method corresponds well with the magnetic enclosed type clamping force tester method, with difference squares less than 0.65 (MPa)², and standard deviations less than 0.11 MPa. Ultrasonic parameters influence measurement results, with larger ultrasonic probe wafer diameter and higher ultrasonic probe frequency producing better measurement accuracy. Additionally, measurement accuracy is insensitive to the sampling frequency of ultrasonic signals. The proposed method has the advantages of high accuracy and high stability, being non-interfering, non-destructive, low-cost, on-line and with good adherence to health and safety, and it has significant application prospects in injection molding production.

[Determination of acrylonitrile in injection molding process: data analysis and recommendations]

Objective: To investigate whether the identification of acrylonitrile, an occupational hazard factor for the industry of injection molding and plastic products, reported in literature is reasonable, and to put forward some recommendations. Methods: Professional articles published from 1990 to 2016 were searched, and an analysis was performed for the data on the determination of acrylonitrile in the industry of injection molding and plastic products from 2003 to 2016 in Longhua Center for Disease Control and Prevention of Shenzhen. Results: According to the literature, the detection rate of acrylonitrile was 10.7%, and the detection results did not exceed the limit. Conclusion: At present, acrylonitrile may not be used as a routine test item for the industry of injection molding and plastic products, in order to save manpower and material resources.

Novel methods reveal that parallelism contributes to the functional vertical slot dimension in ceramic and metal brackets

OBJECTIVES:

To validate a novel method for measuring the clinically relevant bracket slot and use these methods to test the hypothesis that various metal injection molded (MIM) and esthetic ceramic injection molded (CIM) brackets have a bracket slot accuracy within 1 mil (0.001") of their reported slot dimension.

MATERIALS AND METHODS:

A Nikon iNEXIV-VMA-2520 laser microscope was used to measure slots of six series of CIM brackets and two series of MIM brackets via a vision measuring system of 256 gray levels to capture each edge of the slot, largely taking out human subjectivity. This system had a maximum permissible error of 2 + 8 L/1000 μm with a point resolution of 0.1 μm and was estimated to be more accurate than previous methods by a factor of 10. The video image for each bracket was autofocused by a blinded operator, and 40 point-to-line measurements were calculated along the clinical slot and averaged.

RESULTS:

Vertical slot dimension varied from series to series and within the series of brackets. Three of six CIM and two of three MIM brackets had a statistically significant mean slot size 0.001 inches larger than reported. The reported precision of these CIM brackets, as determined from standard deviation, varied from series to series.

CONCLUSIONS:

A novel system that incorporates parallelism into analysis of vertical bracket slot dimension was described. When the entire clinically relevant slot was considered, MIM and CIM brackets had similar precision but were significantly oversized, with contribution from a nonparallel, likely diverging, vertical slot dimension.

Fabrication of tissue engineered osteochondral grafts for restoring the articular surface of diarthrodial joints

Osteochondral allograft implantation is an effective cartilage restoration technique for large defects (>10 cm(2)), though the demand far exceeds the supply of available quality donor tissue. Large bilayered engineered cartilage tissue constructs with accurate anatomical features (i.e. contours, thickness, architecture) could be beneficial in replacing damaged tissue. When creating these osteochondral constructs, however, it is pertinent to maintain biofidelity to restore functionality. Here, we describe a step-by-step framework for the fabrication of a large osteochondral construct with correct anatomical architecture and topology through a combination of high-resolution imaging, rapid prototyping, impression molding, and injection molding.

Effect of structure and viscosity of the components on some properties of starch-rich hybrid blends

Glycerol-plasticized cornstarch and poly(lactic acid) (PLA) were melt-blended alone and at a constant 70:30 (m/m) composition, in the present of an organoclay. The effect of increasing contents of the organoclay on extruded and compression-molded samples was evaluated by X-ray diffraction (XRD), capillary rheometry, thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and tensile tests. XRD and shear viscosity results obtained for the hybrid components (TPS/organoclay and PLA/organoclay) were correlated with the hybrid blends properties. XRD and TGA results suggested that the organoclay was similarly dispersed within both phases. SEM images revealed improved adhesion between the phases. Shear viscosities results indicated improved compatibilization as the organoclay content was increased. Some of the extruded materials were also submitted to injection molding, and characterized by SEM and by tensile tests. For the extruded and compression-molded samples, improved mechanical properties were obtained for the samples with higher contents of the organoclay. For the injection-molded samples, the mechanical properties seemed to be dependent on the organoclay dispersion.