Characterization of Exterior Parts for 3D-Printed Humanoid Robot Arm with Various Patterns and Thicknesses

Currently, metal is the most common exterior material used in robot development due to the need to protect the motor. However, as soft, wearable, and humanoid robots are gradually being developed, many robot parts need to be converted into artificial skin using flexible materials. In this study, in order to develop soft exterior parts for robots, we intended to manufacture exterior robot arm parts via fused filament fabrication (FFF) 3D printing according to various structural and thickness conditions and analyze their mechanical properties. The exterior parts of the robot arms were manufactured utilizing Shore 95 A TPU (eTPU, Esun, Shenzhen, China), which is renowned for its softness and exceptional shock absorption characteristics. The exterior robot arm parts were modeled in two parts, the forearm and upper arm, by applying solid (SL) and re-entrant (RE) structures and thicknesses of 1, 2, and 4 mm. The mechanical properties were analyzed through the use of three-point bending, tensile, and compression testing. All of the characterizations were analyzed using a universal testing machine (AGS-X, SHIMADZU, Kyoto, Japan). After testing the samples, it was confirmed that the RE structure was easily bendable towards the bending curve and required less stress. In terms of the tensile tests, the results were similar to the bending tests; to achieve the maximum point, less stress was required, and for the compression tests, the RE structure was able to withstand the load compared to the SL structure. Therefore, after analyzing all three thicknesses, it was confirmed that the RE structure with a 2 mm thickness had excellent characteristics in terms of bending, tensile, and compressive properties. Therefore, the re-entrant pattern with a 2 mm thickness is more suitable for manufacturing a 3D-printed humanoid robot arm.

Aortic Valve Engineering Advancements: Precision Tuning with Laser Sintering Additive Manufacturing of TPU/TPE Submillimeter Membranes

Synthetic biomaterials play a crucial role in developing tissue-engineered heart valves (TEHVs) due to their versatile mechanical properties. Achieving the right balance between mechanical strength and manufacturability is essential. Thermoplastic polyurethanes (TPUs) and elastomers (TPEs) garner significant attention for TEHV applications due to their notable stability, fatigue resistance, and customizable properties such as shear strength and elasticity. This study explores the additive manufacturing technique of selective laser sintering (SLS) for TPUs and TPEs to optimize process parameters to balance flexibility and strength, mimicking aortic valve tissue properties. Additionally, it aims to assess the feasibility of printing aortic valve models with submillimeter membranes. The results demonstrate that the SLS-TPU/TPE technique can produce micrometric valve structures with soft shape memory properties, resembling aortic tissue in strength, flexibility, and fineness. These models show promise for surgical training and manipulation, display intriguing echogenicity properties, and can potentially be personalized to shape biocompatible valve substitutes.

Highly Sensitive and Wide Detection Range Thermoplastic Polyurethane/Graphene Nanoplatelets Multifunctional Strain Sensor with a Porous and Crimped Network Structure

High-performance flexible strain sensors have tremendous potential applications in wearable devices and health monitoring. However, developing a flexible strain sensor with high sensitivity over a wide strain range remains a significant challenge. In this study, a fibrous membrane with a porous and crimped structure was designed as the substrate material for TPU/GNPs flexible strain sensors. This structural design effectively balances sensitivity with the strain range. The TPU-PEO fibrous membrane prepared using electrospinning with water washing, resulted in a porous fibrous membrane with a TPU framework. Subsequently, the fibrous membrane was subjected to anhydrous ethanol stimulation to obtain a porous and crimped network structure. GNPs were modified on the TPU fibrous membrane through ultrasonic treatment. The produced flexible strain sensor exhibited high sensitivity (GF = 4047.5) within a large strain range (350%) and demonstrated excellent sensing performance, stability, and durability (>10,000 cycles). It not only captured basic movements but also efficiently recognized and measured bending angles, enabling a more sophisticated human-machine interaction experience. This advancement opens up possibilities for future intelligent wearable technology and human-machine interaction, contributing to the evolution of these fields.

Surface Properties of a Biocompatible Thermoplastic Polyurethane and Its Anti-Adhesive Effect against E. coli and S. aureus

Thermoplastic polyurethane (TPU) is a polymer used in a variety of fields, including medical applications. Here, we aimed to verify if the brush and bar coater deposition techniques did not alter TPU properties. The topography of the TPU-modified surfaces was studied via AFM demonstrating no significant differences between brush and bar coater-modified surfaces, compared to the un-modified TPU (TPU Film). The effect of the surfaces on planktonic bacteria, evaluated by MTT assay, demonstrated their anti-adhesive effect on E. coli, while the bar coater significantly reduced staphylococcal planktonic adhesion and both bacterial biofilms compared to other samples. Interestingly, Pearson's R coefficient analysis showed that Ra roughness and Haralick's correlation feature were trend predictors for planktonic bacterial cells adhesion. The surface adhesion property was evaluated against NIH-3T3 murine fibroblasts by MTT and against human fibrinogen and human platelet-rich plasma by ELISA and LDH assay, respectively. An indirect cytotoxicity experiment against NIH-3T3 confirmed the biocompatibility of the TPUs. Overall, the results indicated that the deposition techniques did not alter the antibacterial and anti-adhesive surface properties of modified TPU compared to un-modified TPU, nor its bio- and hemocompatibility, confirming the suitability of TPU brush and bar coater films in the biomedical and pharmaceutical fields.

Fabrication of Oleophilic Polypeptide Nanoparticle from Complexing of Cross-Linked Epsilon-poly-l-lysine with Docusate Sodium for Preparation of Bactericidal Thermoplastic Polyurethanes

Thermoplastic polyurethanes (TPUs) are extensively utilized in the biomedical field due to their exceptional mechanical properties and biocompatibility. However, the lack of antibacterial activity limits their application ranges. Nanoscopic particle-based additives with inherent antibacterial characteristics are regarded as promising strategies to prevent biomaterials-associated infection. Herein, a novel polymeric nanoparticle is prepared, which integrates chemically cross-linked epsilon-poly-l-lysine (CPL) and anionic surfactant-docusate sodium (DS). The cross-linked epsilon-poly-l-lysine/docusate sodium (CPL/DS) nanoparticle can be well dispersed in organic solvent and a polymer matrix, which is beneficial to endowing TPUs with synergistic miscibility and antibacterial properties. An antibacterial test showed that the CPL/DS nanoparticles have strong antibacterial activity against S. aureus. Moreover, the results of antibacterial experiments in vitro revealed that almost 100% of S. aureus could be killed by CPL/DS nanoparticle-embedded TPU film with a content of 0.5 wt %. In addition, all of the CPL/DS modified TPU films showed good cytocompatibility in vitro. Consequently, this kind of CPL/DS nanoplatform has great potential to serve as a safe and high-efficient bactericidal agent for endowing biomedical devices with bactericidal property.

The Laser Selective Sintering Controlled Forming of Flexible TPMS Structures

Sports equipment crafted from flexible mechanical metamaterials offers advantages due to its lightweight, comfort, and energy absorption, enhancing athletes' well-being and optimizing their competitive performance. The utilization of metamaterials in sports gear like insoles, protective equipment, and helmets has garnered increasing attention. In comparison to traditional truss and honeycomb metamaterials, the triply periodic minimal surface lattice structure stands out due to its parametric design capabilities, enabling controllable performance. Furthermore, the use of flexible materials empowers this structure to endure significant deformation while boasting a higher energy absorption capacity. Consequently, this study first introduces a parametric method based on the modeling equation of the triply periodic minimal surface structure and homogenization theory simulation. Experimental results demonstrate the efficacy of this method in designing triply periodic minimal surface lattice structures with a controllable and adjustable elastic modulus. Subsequently, the uniform flexible triply periodic minimal surface lattice structure is fabricated using laser selective sintering thermoplastic polyurethane technology. Compression tests and finite element simulations analyze the hyperelastic response characteristics, including the element type, deformation behavior, elastic modulus, and energy absorption performance, elucidating the stress-strain curve of the flexible lattice structure. Upon analyzing the compressive mechanical properties of the uniform flexible triply periodic minimal surface structure, it is evident that the structure's geometric shape and volume fraction predominantly influence its mechanical properties. Consequently, we delve into the advantages of gradient and hybrid lattice structure designs concerning their elasticity, energy absorption, and shock absorption.

3D Printing of Flexible Mechanical Metamaterials: Synergistic Design of Process and Geometric Parameters

Mechanical metamaterials with ultralight and ultrastrong mechanical properties are extensively employed in various industrial sectors, with three-periodic minimal surface (TPMS) structures gaining significant research attention due to their symmetry, equation-driven characteristics, and exceptional mechanical properties. Compared to traditional lattice structures, TPMS structures exhibit superior mechanical performance. The mechanical properties of TPMS structures depend on the base material, structural porosity (volume fraction), and wall thickness. Hard rigid lattice structures such as Gyroid, diamond, and primitive exhibit outstanding performance in terms of elastic modulus, energy absorption, heat dissipation, and heat transfer. Flexible TPMS lattice structures, on the other hand, offer higher elasticity and recoverable large deformations, drawing attention for use in applications such as seat cushions and helmet impact-absorbing layers. Conventional fabrication methods often fail to guarantee the quality of TPMS structure samples, and additive manufacturing technology provides a new avenue. Selective laser sintering (SLS) has successfully been used to process various materials. However, due to the layer-by-layer manufacturing process, it cannot eliminate the anisotropy caused by interlayer bonding, which impacts the mechanical properties of 3D-printed parts. This paper introduces a process data-driven optimization design approach for TPMS structure geometry by adjusting volume fraction gradients to overcome the elastic anisotropy of 3D-printed isotropic lattice structures. Experimental validation and analysis are conducted using TPMS structures fabricated using TPU material via SLS. Furthermore, the advantages of volume fraction gradient-designed TPMS structures in functions such as energy absorption and heat dissipation are explored.

Optimization of Piezoresistive Response of Elastomeric Porous Structures Based on Carbon-Based Hybrid Fillers Created by Selective Laser Sintering

Recently, piezoresistive sensors made by 3D printing have gained considerable interest in the field of wearable electronics due to their ultralight nature, high compressibility, robustness, and excellent electromechanical properties. In this work, building on previous results on the Selective Laser Sintering (SLS) of porous systems based on thermoplastic polyurethane (TPU) and graphene (GE)/carbon nanotubes (MWCNT) as carbon conductive fillers, the effect of variables such as thickness, diameter, and porosity of 3D printed disks is thoroughly studied with the aim of optimizing their piezoresistive performance. The resulting system is a disk with a diameter of 13 mm and a thickness of 0.3 mm endowed with optimal reproducibility, sensitivity, and linearity of the electrical signal. Dynamic compressive strength tests conducted on the proposed 3D printed sensors reveal a linear piezoresistive response in the range of 0.1-2 N compressive load. In addition, the optimized system is characterized at a high load frequency (2 Hz), and the stability and sensitivity of the electrical signal are evaluated. Finally, an application test demonstrates the ability of this system to be used as a real-time wearable pressure sensor for applications in prosthetics, consumer products, and personalized health-monitoring systems.

Robotization of Three-Point Bending Mechanical Tests Using PLA/TPU Blends as an Example in the 0-100% Range

This article presents the development of an automated three-point bending testing system using a robot to increase the efficiency and precision of measurements for PLA/TPU polymer blends as implementation high-throughput measurement methods. The system operates continuously and characterizes the flexural properties of PLA/TPU blends with varying TPU concentrations. This study aimed to determine the effect of TPU concentration on the strength and flexural stiffness, surface properties (WCA), thermal properties (TGA, DSC), and microscopic characterization of the studied blends.

A Study on Tencel/LMPET-TPU/Triclosan Laminated Membranes: Excellent Water Resistance and Antimicrobial Ability

Medical product contamination has become a threatening issue against human health, which is the main reason why protective nonwoven fabrics have gained considerable attention. In the present, there is a soaring number of studies on establishing protection systems with nonwoven composites via needle punch. Meanwhile, the disadvantages of composites, such as poor mechanical performance and texture, impose restrictions. Hence, in this study, an eco-friendly method composed of needling, hot pressing, and lamination is applied to produce water-resistant, windproof, and antimicrobial Tencel/low-melting-point polyester-thermoplastic polyurethane/Triclosan (Tencel/LMPET-TPU/TCL) laminated membranes. Field-emission scanning electron microscope (SEM) images and FTIR show needle-punched Tencel/LMPET membranes successfully coated with TPU/TCL laminated membranes, thereby extensively improving nonwoven membranes in terms of water-resistant, windproof, and antimicrobial attributes. Parameters including needle punch depth, content of LMPET fibers, and concentration of TCL are changed during the production. Specifically, Tencel/LMPET-TPU/TCL-0.1 laminated nonwovens acquire good water resistance (100 kPa), outstanding windproof performance (<0.1 cm3/cm2/s), and good antimicrobial ability against Escherichia coli and Staphylococcus aureus. Made with a green production process that is pollution-free, the proposed products are windproof, water resistant, and antimicrobial, which ensures promising uses in the medical and protective textile fields.

Co-Influence of Nanofiller Content and 3D Printing Parameters on Mechanical Properties of Thermoplastic Polyurethane (TPU)/Halloysite Nanotube (HNT) Nanocomposites

Thermoplastic polyurethane (TPU) belongs to a polyurethane family that possesses an elongation much higher than 300%, despite having low mechanical strength, which can be overcome by incorporating clay-based halloysite nanotubes (HNTs) as additives to manufacture TPU/HNT nanocomposites. This paper focuses on the co-influence of HNT content and 3D printing parameters on the mechanical properties of 3D printed TPU/HNT nanocomposites in terms of tensile properties, hardness, and abrasion resistance via fused deposition modelling (FDM). The optimum factor-level combination for different responses was determined with the aid of robust statistical Taguchi design of experiments (DoEs). Material characterisation was also carried out to evaluate the surface morphology, nanofiller dispersion, chemical structure, thermal stability, and phase behaviour corresponding to the DoE results obtained. It is evidently shown that HNT level and infill density play a significant role in impacting mechanical properties of 3D-printed TPU/HNT nanocomposites.

Carboxylated Graphene Oxide (c-GO) Embedded ThermoPlastic Polyurethane (TPU) Mixed Matrix Membrane with Improved Physicochemical Characteristics

Water is an important component of our life. However, the unavailability of fresh water and its contamination are emerging problems. The textile industries are the major suppliers of contamination of water, producing high concentrations of heavy metals and hazardous dyes posing serious health hazards. Several technologies for water purification are available in the market. Among them, the membrane technology is a highly advantageous and facile strategy to remediate wastewater. Herein, the distinguished combination of pore-forming agents, solvent, and nanoparticles has been used to achieve improved functioning of the polymeric composite membranes. To do so, graphene oxide (GO) was fabricated via Hummer's technique and GO functionalization using chloroacetic acid (c-GO) was performed. Thermoplastic polyurathane (TPU) membranes having different concentrations c-GO were made using the phase inversion technique. Scanning electron microscopy (SEM), Fourier transforms infrared spectroscopy (FT-IR), and X-ray diffraction (XRD) was used to examine surface morphology, chemical functionalities on membranes surfaces, and crystallinity of membranes, respectively. The temperature-dependent behavior of c-GO composite membranes has been analyzed using DSC technique. The water contact angle measurements were performed for the estimation of hydrophilicity of the c-GO based TPU membrane. The improved water permeability of the composite membrane was observed with increasing the c-GO concentration in polymeric membranes. c-GO was observed as a potential candidate that enhanced membrane physicochemical properties. The proposed membranes can behave as efficient candidates in multiple domains of environmental remediation. Furthermore, the improved dye rejection characteristics of proposed composite membranes suggest that the membranes can be best suited for wastewater treatment as well.

DMA of TPU Films and the Modelling of Their Viscoelastic Properties for Noise Reduction in Jet Engines

Due to current developments in jet engine design, the acoustic performance of conventional acoustic liners needs to be improved with respect to lower frequency spectrums and broadband absorption. In this context, the present study aimed to determine the viscoelastic material properties of a thermoplastic polyurethane (TPU) film for targeted application in novel acoustic liners with integrated film material for enhanced noise reduction. Therefore, a dynamic mechanical analysis (DMA) was performed to determine these viscoelastic material properties. Based on the acquired data, the time-temperature shift (TTS) was applied to obtain the material's temperature- and frequency-dependent mechanical properties. In this regard, the William-Landel-Ferry (WLF) method and an alternative polynomial approach determining the shift factors were investigated and compared. Furthermore, a generalized Maxwell model-so-called Prony-series-with and without pre-smoothing utilizing of a fractional rheological model was applied to approximate the measured storage and loss modulus and to provide a material model that can be used in finite element analyses. Finally, the results were discussed concerning the application of the films in acoustic liners under the conditions of a standard flight cycle and the applied loads. The present investigations thus provide a method for characterizing polymer materials, approximating their mechanical behavior for vibration applications at different ambient temperatures and enabling the identification of their operational limits during the application in acoustic liners.

3D Printable Thermoplastic Polyurethane Energy Efficient Passive Foot

Passive energy storing prosthetics are redesigned to improve the stored and recovered energy during different phases of the gait cycle. Furthermore, the demand of the low-cost passive prosthesis that are capable of energy storing is increasing day by day especially in underdeveloping countries. This article proposes a new passive foot design that is more energy efficient if 3D printed using thermoplastic polyurethane (TPU) material. The model is built in SOLIDWORKS®, and then the finite element analysis is conducted on ANSYS®. Two models of the foot are designed with and without Steps on the toe and heel, where the difference of Steps showed difference in the energy stored in the foot during stimulation. TPU being a flexible material with high strength and durability is chosen as the material for the 3D printed foot. The analysis performed on the foot is for an 80 kg person at different angles during the gait cycle for the K2 human activity level. The results obtained indicate high energy storage ability of TPU that is 0.044 J/Kg, comparative to other materials Hytrel, Delrin, and Carbon Fiber DA that are commonly used in passive foots.

Soft CNT-Polymer Composites for High Pressure Sensors

Carbon−polymer composite-based pressure sensors have many attractive features, including low cost, easy integration, and facile fabrication. Previous studies on carbon−polymer composite sensors focused on very high sensitivities for low pressure ranges (10 s of kPa), which saturate quickly at higher pressures and thus are ill-suited to measure the high pressure ranges found in various applications, including those in underwater (>1 atm, 101 kPa) and industrial environments. Current sensors designed for high pressure environments are often difficult to fabricate, expensive, and, similarly to their low-pressure counterparts, have a narrow sensing range. To address these issues, this work reports the design, synthesis, characterization, and analysis of high-pressure TPU-MWCNT based composite sensors, which detect pressures from 0.5 MPa (4.9 atm) to over 10 MPa (98.7 atm). In this study, the typical approach to improve sensitivity by increasing conductive additive concentration was found to decrease sensor performance at elevated pressures. It is shown that a better approach to elevated pressure sensitivity is to increase sensor response range by decreasing the MWCNT weight percentage, which improves sensing range and resolution. Such sensors can be useful for measuring high pressures in many industrial (e.g., manipulator feedback), automotive (e.g., damping elements, bushings), and underwater (e.g., depth sensors) applications.

Facile Fabrication of Highly Sensitive Thermoplastic Polyurethane Sensors with Surface- and Interface-Impregnated 3D Conductive Networks

This research aims to develop a practical, scalable, and highly conductive flexible 3D printed piezoresistive sensor with low filler content. Here, we introduced a fused deposition modeling 3D printing combined in situ spray-coating technique to develop a conductive sensor in a single shot. The graphene suspension is sprayed over each layer during the 3D printing of the sensor, which helps develop a conductive network on the surface and at the interface of the printed system. Graphene deposited on the overall surface is often affected by nanoparticle delamination and loses its function over time. To avoid this, the prepared samples are subjected to foaming. The foaming process created a low-mass-density sensor by forming a microcellular structure, and the surface-deposited graphene is embedded well on the TPU surface. The method followed in this work reveals a stable and connected conduction path with excellent electrical resistance and resistance against harsh conditions (exposure to organic solvents). Besides, the compression sensor withstood its sensitivity over a severe compressive strain of 80% and showed a GF of 1.82 and a sensitivity of 2.316 kPa^-1. The conductive network path varied based on the infill pattern, affecting its electrical sensitivity. The wiggle pattern shows good resistance; under stretching, the pattern generated a higher current and showed a delayed conductive path disconnection than other patterns. Thus, the embedded graphene/TPU conductive sensors show good stability and promising sensitivity. Furthermore, the developed sensor is used to monitor human motion and actions.

Macromolecule Relaxation Directed 3D Nanofiber Architecture in Stretchable Fibrous Mats for Wearable Multifunctional Sensors

Elastomer fiber mat sensors, which are capable of perceiving mechanical stimuli, temperature, and vapor of chemicals, are highly desirable for designing wearable electronics and human-robot interfacing devices due to good wearability, skin affinity, and durability, and so on. However, it is still challenging to fabricate multiresponsive flexible wearable sensors with three-dimensional (3D) architecture using simple material and structure design. Herein, we report an all-in-one multiresponsive thermoplastic polyurethane (TPU) nanofiber mat sensors composed of crimped elastomer fibers with deposited platinum nanoparticles (PtNPs) on the fiber surface. The 1D TPU nanofibers could be transferred to nanofibers with different 3D nanofiber architectures by controllable macromolecular chain relaxation of aligned elastomer polymers upon poor solvent annealing. The conductive networks of PtNPs on wavy TPU fibers enable the sensor susceptible to multiple stimuli like strain/pressure, humidity, and organic vapors. Besides, the 3D nanofiber architectures allow the strain sensor to detect wider tensile strain and pressure with higher sensitivity due to delicate fiber morphology and structure control. Therefore, this work provides new insights into the fabrication of multifunctional flexible sensors with 3D architecture in an easy way, advancing the establishment of a multiple signal monitoring platform for the health care and human-machine interfacing.

Surface Modification of Ammonium Polyphosphate for Enhancing Flame-Retardant Properties of Thermoplastic Polyurethane

Currently, the development of efficient and environmentally friendly flame-retardant thermoplastic polyurethane (TPU) composite materials has caused extensive research. Ammonium polyphosphate (APP) is used as a general intumescent flame retardant to improve the flame retardancy of TPU. In this paper, we developed a functionalized APP flame retardant (APP-Cu@PDA). Adding only 5 wt% of APP-Cu@PDA into TPU can significantly improve the flame-retardant's performance of the composite material, reflected by a high LOI value of 28% with a UL-94 test of V-0 rating. Compared with pure TPU, the peak heat release rate, total heat release, peak smoke release rate, and total smoke release were reduced by 82%, 25%, 50%, and 29%, respectively. The improvements on the flame-retardant properties of the TPU/5%APP-Cu@PDA composites were due to the following explanations: Cu²⁺-chelated PDA has a certain catalytic effect on the carbonization process, which can promote the formation of complete carbon layers and hinder the transfer of heat and oxygen. In addition, after adding 5% APP-Cu@PDA, the tensile strength and elongation at the break of TPU composites did not decrease significantly. In summary, we developed a new flame-retardant APP-Cu@PDA, which has better flame-retardant properties than many reported TPU composites, and its preparation process is simple and environmentally friendly. This process can be applied to the industrial production of flame retardants in the future.

Strain Rate Sensitivity of Polycarbonate and Thermoplastic Polyurethane for Various 3D Printing Temperatures and Layer Heights

In this work, strain rate sensitivity was studied for 3D-printed polycarbonate (PC) and thermoplastic polyurethane (TPU) materials. Specimens were fabricated through fused filament fabrication (FFF) additive manufacturing (AM) technology and were tested at various strain rates. The effects of two FFF process parameters, i.e., nozzle temperature and layer thickness, were also investigated. A wide analysis for the tensile strength (MPa), the tensile modulus of elasticity (MPa), the toughness (MJ/m³) and the strain rate sensitivity index ‘m’ was conducted. Additionally, a morphological analysis was conducted using scanning electron microscopy (SEM) on the side and the fracture area of the specimens. Results from the different strain rates for each material were analyzed, in conjunction with the two FFF parameters tested, to determine their effect on the mechanical response of the two materials. PC and TPU materials exhibited similarities regarding their temperature response at different strain rates, while differences in layer height emerged regarding the appropriate choice for the FFF process. Overall, strain rate had a significant effect on the mechanical response of both materials.

Influence of the Halloysite Nanotube (HNT) Addition on Selected Mechanical and Biological Properties of Thermoplastic Polyurethane

Halloysite nanotube (HNT) additions to the thermoplastic polyurethane (TPU) system were thoroughly evaluated in this study. The resultant composites have been designed for future personalized intervertebral disc implant applications, which requires additional technology to obtain the appropriate geometry unique to each patient. These requirements can be fulfilled using 3D printing. In this work, a technology was developed to produce filaments for fused deposition modeling (FDM). Nanocomposites were prepared using variable HNT content (1, 2, and 3 wt.%). The nanostructure of the resultant composites was confirmed using scanning transmission electron microscopy (STEM). Mechanical tests were used to measure the tensile modulus, stress, and elongation the composites and TPU matrix. Nanocomposites with 2% HNT content were able to withstand 26% increased stress and 50% increased elongation compared to pure TPU before fracturing in addition to a 13% reduction in the friction coefficient. A MTT cytotoxicity assay confirmed the cytotoxicity of all tested materials against human epidermal keratinocyte cells (HaCaT).

Measurement of Nonlinear Poisson's Ratio of Thermoplastic Polyurethanes under Cyclic Softening Using 2D Digital Image Correlation

Thermoplastic polyurethanes (TPUs) and other elastomers are widely used in many applications for the advantages they provide in terms of high elasticity, lightness, resistance to breakage, and impact resistance. These materials exhibit strong hysteresis in the large strain stress-strain behavior, known as cyclic softening or the Mullins effect. Despite the extensive studies on this phenomenon and the importance of Poisson’s ratio, how the Poisson’s ratio of these materials changes during cyclic uniaxial tests is still unclear. Here, we measure the nonlinear Poisson’s ratio of TPU and investigate its correlation with cyclic softening using two-dimensional digital image correlation (2D-DIC) combined with the reference sample compensation (RSC) method. This accuracy-enhanced method can effectively eliminate the measurement errors induced by the unavoidable out-of-plane displacements and lens distortion. We find that the Poisson’s ratio of TPUs also exhibits large hysteresis in the first cycle and then approaches a steady state in subsequent cycles. Specifically, it starts from a relatively low value of 0.45 ± 0.005 in the first loading, then increases to 0.48 ± 0.005 in the first unloading, and remains largely constant afterward. Such a change in the Poisson’s ratio results in a slight volume increase (≈1%) at a maximum strain of 17.5%. Our findings are useful for those who use finite element method to analyze the mechanical behavior of TPU, and shed new light on understanding the physical origin of cyclic softening.

Melt Spinning of Highly Stretchable, Electrically Conductive Filament Yarns

Electrically conductive fibers are required for various applications in modern textile technology, e.g., the manufacturing of smart textiles and fiber composite systems with textile-based sensor and actuator systems. According to the state of the art, fine copper wires, carbon rovings, or metallized filament yarns, which offer very good electrical conductivity but low mechanical elongation capabilities, are primarily used for this purpose. However, for applications requiring highly flexible textile structures, as, for example, in the case of wearable smart textiles and fiber elastomer composites, the development of electrically conductive, elastic yarns is of great importance. Therefore, highly stretchable thermoplastic polyurethane (TPU) was compounded with electrically conductive carbon nanotubes (CNTs) and subsequently melt spun. The melt spinning technology had to be modified for the processing of highly viscous TPU–CNT compounds with fill levels of up to 6 wt.% CNT. The optimal configuration was achieved at a CNT content of 5 wt.%, providing an electrical resistance of 110 Ωcm and an elongation at break of 400%.

Polyurethane-Based Coatings with Promising Antibacterial Properties

In coatings technology, the possibility of introducing specific characteristics at the surface level allows for the manufacture of medical devices with efficient and prolonged antibacterial properties. This efficiency is often achieved by the use of a small amount of antibacterial molecules, which can fulfil their duty while limiting eventual releasing problems. The object of this work was the preparation and characterization of silver, titanium dioxide and chitosan polyurethane-based coatings. Coatings with the three antibacterials were prepared using different deposition techniques, using a brush or a bar coater automatic film applicator, and compared to solvent casted films prepared with the same components. For silver containing materials, an innovative strategy contemplating the use and preparation of silver nanoparticles in a single step-method was employed. This preparation was obtained starting from a silver precursor and using a single compound as the reducing agent and stabilizer. Ultraviolet-visible spectroscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, contact angle measurements and adhesion test experiments were used to characterize the prepared coatings. Promising antibacterial properties, measured via direct and indirect methods, were registered for all the silver-based materials.

On the Synergistic Effect of Multi-Walled Carbon Nanotubes and Graphene Nanoplatelets to Enhance the Functional Properties of SLS 3D-Printed Elastomeric Structures

Elastomer-based porous structures realized by selective laser sintering (SLS) are emerging as a new class of attractive multifunctional materials. Herein, a thermoplastic polyurethane (TPU) powder for SLS was modified by 1 wt.% multi-walled carbon nanotube (MWCNTs) or a mixture of MWCNTs and graphene (GE) nanoparticles (70/30 wt/wt) in order to investigate on both the synergistic effect provided by the two conductive nanostructured carbonaceous fillers and the correlation between formulation, morphology, and final properties of SLS printed porous structures. In detail, porous structures with a porosity ranging from 20% to 60% were designed using Diamond (D) and Gyroid (G) unit cells. Results showed that the carbonaceous fillers improve the thermal stability of the elastomeric matrix. Furthermore, the TPU/1 wt.% MWCNTs-GE-based porous structures exhibit excellent electrical conductivity and mechanical strength. In particular, all porous structures exhibit a robust negative piezoresistive behavior, as demonstrated from the gauge factor (GF) values that reach values of about −13 at 8% strain. Furthermore, the G20 porous structures (20% of porosity) exhibit microwave absorption coefficients ranging from 0.70 to 0.91 in the 12–18 GHz region and close to 1 at THz frequencies (300 GHz–1 THz). Results show that the simultaneous presence of MWCNTs and GE brings a significant enhancement of specific functional properties of the porous structures, which are proposed as potential actuators with relevant electro-magnetic interference (EMI) shielding properties.

Biofunctional Glycol-Modified Polyethylene Terephthalate and Thermoplastic Polyurethane Implants by Extrusion-Based Additive Manufacturing for Medical 3D Maxillofacial Defect Reconstruction

This work addresses the topic of extrusion-based additive manufacturing (filament-based material extrusion) of patient-specific biofunctional maxillofacial implants. The technical approach was chosen to overcome the shortcomings of medically established fabrication processes such as a limited availability of materials or long manufacturing times. The goal of the work was a successful fabrication of basic implants for defect reconstruction. The underlying vision is the implants' clinic-internal and operation-accompanying application. Following a literature search, a material selection was conducted. Digitally prepared three-dimensional (3D) models dealing with two representative mandible bone defects were printed based on the material selection. An ex-vivo model of the implant environment evaluated dimensional and fitting traits of the implants. Glycol-modified PET (PETG) and thermoplastic polyurethane (TPU) were finally selected. These plastics had high cell acceptance, good mechanical properties, and optimal printability. The subsequent fabrication process yielded two different implant strategies: the standard implant made of PETG with a build-up rate of approximately 10 g/h, and the biofunctional performance implant with a TPU shell and a PETG core with a build-up rate of approximately 4 g/h. The standard implant is meant to be intraoperatively applied, as the print time is below three hours even for larger skull defects. Standard implants proved to be well fitting, mechanically stable and cleanly printed. In addition, the hybrid implant showed particularly cell-friendly behavior due to the chemical constitution of the TPU shell and great impact stability because of the crack-absorbing TPU/PETG combination. This biofunctional constellation could be used in specific reconstructive patient cases and is suitable for pre-operative manufacturing based on radiological image scans of the defect. In summary, filament-based material extrusion has been identified as a suitable manufacturing method for personalized implants in the maxillofacial area. A further clinical and mechanical study is recommended.

Polyurethane-Based Composites: Effects of Antibacterial Fillers on the Physical-Mechanical Behavior of Thermoplastic Polyurethanes

The challenge to manufacture medical devices with specific antibacterial functions, and the growing demand for systems able to limit bacterial resistance growth, necessitates the development of new technologies which can be easily produced at an industrial level. The object of this work was the study and the development of silver, titanium dioxide, and chitosan composites for the realization and/or implementation of biomedical devices. Thermoplastic elastomeric polyurethane was selected and used as matrix for the various antibacterial functions introduced during the processing phase (melt compounding). This strategy was employed to directly incorporate antimicrobial agents into the main constituent material of the devices themselves. With the exception of the composite filled with titanium dioxide, all of the other tested composites were shown to possess satisfactory mechanical properties. The best antibacterial effects were obtained with all the composites against Staphylococcus aureus: viability was efficiently inhibited by the prepared materials in four different bacterial culture concentrations.

Interface Design Strategy for the Fabrication of Highly Stretchable Strain Sensors

Simultaneously achieving high piezoresistive sensitivity, stretchability, and good electrical conductivity in conductive elastomer composites (CECs) with carbon nanofillers is crucial for stretchable strain sensor and electrode applications. Here, we report a facile and environmentally friendly strategy to realize these three goals at once by using branched carbon nanotubes, also known as the carbon nanostructure (CNS). Inspired by the brick-wall structure, a robust segregated conductive network of a CNS is formed in the thermoplastic polyurethane (TPU) matrix at a very low filler fraction, which renders the composite very good electrical, mechanical, and piezoresistive properties. An extremely low percolation threshold of 0.06 wt %, currently the lowest for TPU-based CECs, is achieved via this strategy. Meanwhile, the electrical conductivity is up to 1 and 40 S/m for the composites with 0.7 and 4 wt % CNS, respectively. Tunable piezoresistive sensitivity dependent on CNS content is obtained, and the composite with 0.7 wt % filler has a gauge factor up to 6861 at strain ε = 660% (elongation at break is 950%). In addition, this strategy also renders the composites' attractive tensile modulus. The composite with 3 wt % CNS shows 450% improvement in Young's modulus versus neat TPU. This work introduces a facile strategy to fabricate highly stretchable strain sensors by designing CNS network structures, advancing understanding of the effects of polymer-filler interfaces on the mechanical and electrical property enhancements for polymer nanocomposites.