Influence of Raster Pattern on Residual Stress and Part Distortion in FDM of Semi-Crystalline Polymers: A Simulation Study.

In fused deposition modelling (FDM) based on the selected raster pattern, the developed internal thermal residual stresses can vary considerably affecting the mechanical properties and leading to distinct part distortions. This phenomenon is more pronounced in semi-crystalline than amorphous polymers due to crystallisation. Hence, this study focuses on the simulation of the FDM process of a semi-crystalline polymer (polypropylene) with raster patterns such as line (90°/90°), line (0°/90°), zigzag (45°/45°), zigzag (45°/-45°), and concentric from Cura (slicing software). The simulation provides visualisation and prediction of the internally developed thermal residual stresses and resulting warpage with printing time and temperature. The sample with a line (90°/90°) raster pattern is considered as the reference sample in order to compare the relative levels of residual stress and warpage in the other printed/simulated samples. Among the considered raster patterns, the concentric pattern displays the lowest amount of warpage (5.5% decrease) along with a significant drop in residual stress of 21%. While the sample with a zigzag (45°/-45°) pattern showed the highest increase of 37% in warpage along with a decrease of 9.8% in residual stresses. The sample with a zigzag (45°/45°) pattern, exhibited a considerable increase of 16.2% in warpage with a significant increase of 31% in residual stresses. Finally, the sample with a line (0°/90°) raster pattern displayed an increase of 24% increase in warpage with an increase of 6.6% in residual stresses.

3D Printed Strontium and Zinc Doped Hydroxyapatite Loaded PEEK for Craniomaxillofacial Implants.

In this study, Strontium (Sr) and Zinc (Zn) doped-HA nanoparticles were synthesized and incorporated into polyetheretherketone (PEEK) up to 30 wt.% and processed by a novel approach i.e., fused deposition modelling (FDM) 3D printing for the production of patient specific cranial implants with improved bioactivity and the required mechanical performance. Filaments were produced via extrusion and subsequently 3D-printed using FDM. To further improve the bioactivity of the 3D-printed parts, the samples were dip-coated in polyethylene glycol-DOPA (PEG-DOPA) solution. The printing quality was influenced by filler loading, but was not significantly influenced by the nature of doped-HA. Hence, the printing conditions were optimized for each sample. Micro-CT and Scanning Electron Microscopy (SEM) showed a uniform distribution of bioceramic particles in PEEK. Although agglomeration of particles increased with increase in filler loadings. Differential Scanning Calorimetry (DSC) showed that the melting point and crystallinity of PEEK increased with an increase in doped-HA loading from 343 °C to 355 °C and 27.7% to 34.6%, respectively. Apatite formation was confirmed on the 3D-printed samples after immersion in simulated body fluid (SBF) for 7, 14 and 28 days via SEM, X-ray diffraction (XRD) and Fourier Transform Infrared Spectroscopy (FTIR). The tensile strength and impact strength decreased from 75 MPa to 51 MPa and 14 kJ/m2 to 4 kJ/m2, respectively, while Young's modulus increased with increasing doped-HA content from 2.8 GPa to 4.2 GPa. However, the tensile strengths of composites remained in the range of human cortical bone i.e., ≥50 MPa. In addition, there was a slight increase in mechanical strength after 28 days immersion which was attributed to apatite formation. Water contact angle showed that the hydrophilicity of the samples improved after coating the 3D-printed samples with PEG-DOPA. Hence, based on the results, the 3D-printed PEEK nanocomposites with 20 wt.% doped-HA is selected as the best candidate for the 3D-printing of craniomaxillofacial implants.

Influence of Ambient Temperature on Part Distortion: A Simulation Study on Amorphous and Semi-Crystalline Polymer.

Semi-crystalline polymers develop higher amounts of residual stress and part distortion (warpage) compared to amorphous polymers due to their crystalline nature. Additionally, the FDM processing parameters such as ambient temperature play an important role in the resulting residual stresses and part distortion of the printed part. Hence, in this study, the effect of ambient temperature on the in-built residual stresses and warpage of amorphous acrylonitrile-butadiene-styrene (ABS) and semi-crystalline polypropylene (PP) polymers was investigated. From the results, it was observed that increasing the ambient temperature from 50 °C to 75 °C and further to 120 °C resulted in 0.22-KPa and 0.37-KPa decreases in residual stress of ABS, but no significant change in the amount of warpage. For PP, increasing ambient temperature from 50 °C to 75 °C led to a more considerable decrease in residual stress (0.5 MPa) and about 3% increase in warpage. Further increasing to 120 °C resulted in a noticeable 2 MPa decrease in residual stress and a 3.4% increase in warpage. Reduction in residual stress in both ABS and PP as a result of increasing ambient temperature was due to the reduced thermal gradients. The enhanced warpage in PP with increase in ambient temperature, despite the reduction in residual stress, was ascribed to crystallization and shrinkage.

Elastic Modulus and Flatwise (Through-Thickness) Tensile Strength of Continuous Carbon Fibre Reinforced 3D Printed Polymer Composites.

Additively manufactured composite specimens exhibit anisotropic properties, meaning that the elastic response changes with respect to orientation. Both in-plane and out-of-plane mechanical properties are important for designing purpose. Recent studies have characterised the in-plane performance. In this study, however, through-thickness tensile strength of 3D polymer composites were determined by printing of continuous carbon fibre reinforced thermoplastic polyamide-based composite, manufactured using a Markforged Two 3D printer. This paper discusses sample fabrication and geometry, adhesive used, and testing procedure. Test standards used to determine out-of-plane properties are tedious as most of the premature failures occur between the specimens and the tabs. Two types of samples were printed according to ASTM flatwise tension standard and the results were compared to determine the geometry effect on the interlaminar strength. This test method consists of subjecting the printed sample to a uniaxial tensile force normal to the plane. With this method, the acceptable failure modes for tensile strength must be internal to the structure, not between the sample and the end tabs. Micro-computed tomography (µCT) was carried out to observe the porosity. Surface behaviour was studied using scanning electron microscopy (SEM) to see the voids and the distribution of the fibres in the samples. The results showed consistent values for tensile strength and elastic modulus for Araldite glue after initial trials (with some other adhesives) to determine a suitable choice of adhesive for bonding the samples with the tabs. Circular specimens have higher tensile strength and elastic modulus as compared to rectangular specimens.

3D printed PEEK/HA composites for bone tissue engineering applications: Effect of material formulation on mechanical performance and bioactive potential.

Polyetheretherketone (PEEK) is a biocompatible polymer widely used for biomedical applications. Because it is biologically inert, bioactive phases, such as nano-hydroxyapatite (HA), have been added to PEEK in order to improve its bioactivity. 3D printing (3DP) technologies are being increasingly used today to manufacture patient specific devices and implants. However, processing of PEEK is challenging due to its high melting point which is above 340 °C. In this study, PEEK-based filaments containing 10 wt% of pure nano-HA, strontium (Sr)- doped nano-HA and Zinc (Zn)-doped nano-HA were produced via hot-melt extrusion and subsequently 3D printed via fused deposition modelling (FDM), following an initial optimization process. The raw materials, extruded filaments and 3D printed samples were characterized in terms of physicochemical, thermal and morphological analysis. Moreover, the mechanical performance of 3D printed specimens was assessed via tensile tensing. Although an increase in the melting point and a reduction in crystallization temperature was observed with the addition of HA and doped HA to pure PEEK, there was no noticeable increase in the degree of crystallinity. Regarding the mechanical behavior, no significant differences were detected following the addition of the inorganic phases to the polymeric matrix, although a small reduction in the ultimate tensile strength (~14%) and Young's modulus (~5%) in PEEK/HA was observed in comparison to pure PEEK. Moreover, in vitro bioactivity of 3D printed samples was evaluated via a simulated body fluid immersion test for up to 28 days; the formation of apatite was observed on the surfaces of sample surfaces containing HA, SrHA and ZnHA. These results indicate the potential to produce bioactive, 3DP PEEK composites for challenging applications such as in craniofacial bone repair.

Simultaneous enhancement of electrical conductivity and interlaminar fracture toughness of carbon fiber/epoxy composites using plasma-treated conductive thermoplastic film interleaves.

Multiwalled carbon nanotube (MWCNT)-doped polyamide 12 (PA12) films with various nanofiller loadings were prepared via a solution casting method to simultaneously improve the electrical conductivity and fracture toughness of carbon fiber/epoxy (CF/EP) composites. The films were interleaved between CF/EP prepreg layers and melted to bond with the matrix during the curing process. To improve the interfacial compatibility and adhesion between the conductive thermoplastic films (CTFs) and the epoxy matrix, the CTFs were perforated and then subjected to a low temperature oxygen plasma treatment before interleaving. Fourier transform infrared (FTIR) spectra results confirm that oxygen-containing functional groups were introduced on the surface of the CTFs, and experimental results demonstrate that the electrical conductivity of the laminates was significantly improved. There was a 2-fold increase in the transverse direction electrical conductivity of the laminate with 0.7 wt% MWCNT loading and a 21-fold increase in the through-thickness direction. Double cantilever beam (DCB) tests demonstrated that the Mode-I fracture toughness (G IC) and resistance (G IR) of the same laminates significantly increased by 59% and 113%, respectively. Enhancements of both interlaminar fracture toughness and electrical conductivity are mainly attributed to the strong interfacial adhesion achieved after plasma treatment and to the bridging effect of the carbon nanotubes.

Electrical methods of controlling bacterial adhesion and biofilm on device surfaces.

This review will summarize the significant body of research within the field of electrical methods of controlling the growth of microorganisms. We examine the progress from early work using current to kill bacteria in static fluids to more realistic treatment scenarios such as flow-through systems designed to imitate the human urinary tract. Additionally, the electrical enhancement of biocide and antibiotic efficacy will be examined alongside recent innovations including the biological applications of acoustic energy systems to prevent bacterial surface adherence. Particular attention will be paid to the electrical engineering aspects of previous work, such as electrode composition, quantitative electrical parameters and the conductive medium used. Scrutiny of published systems from an electrical engineering perspective will help to facilitate improved understanding of the methods, devices and mechanisms that have been effective in controlling bacteria, as well as providing insights and strategies to improve the performance of such systems and develop the next generation of antimicrobial bioelectric materials.

Influence of annealing on chain entanglement and molecular dynamics in weak dynamic asymmetry polymer blends.

The influence of annealing above the glass transition temperature (T(g)) on chain entanglement and molecular dynamics of solution-cast poly(methyl methacrylate)/poly(styrene-co-maleic anhydride) (PMMA/SMA) blends was investigated via a combination of dynamic rheological measurement and broadband dielectric spectroscopy. Chain entanglement density increases when the annealing temperature and/or time increases, resulting from the increased efficiency of chain packing and entanglement recovery. The results of the annealing treatment without cooling revealed that the increase of the entanglement density occurred during the annealing process instead of the subsequent cooling procedure. Annealing above T(g) exerts a profound effect on segmental motion, including the transition temperature and dynamics. Namely, T(g) shifts to higher temperatures and the relaxation time (τ(max)) increases due to the increased entanglement density and decreased molecular mobility. Either T(g) or τ(max) approaches an equilibrium value gradually, corresponding to the equilibrium entanglement density that might be obtained through the theoretical predictions. However, no obvious distribution broadening is observed due to the unchanged heterogeneous dynamics. Furthermore, side group rotational motion could be freely achieved without overcoming the chain entanglement resistance. Hence, neither the dynamics nor the distribution width of the subglass relaxation (ß- and γ-relaxation) processes is affected by chain entanglement resulting from annealing, indicating that the local environment of the segments is unchanged.

Surface modification of poly(epsilon-caprolactone) using a dielectric barrier discharge in atmospheric pressure glow discharge mode.

The role of roughening and functionalization processes involved in modifying the wettability of poly(epsilon-caprolactone) (PCL) after treatment by an atmospheric pressure glow discharge plasma is discussed. The change in the ratio of CO/C-O bonds is a significant factor influencing the wettability of PCL. As the contact angle decreases, the level of CO bonds tends to rise. Surface roughness alterations are the driving force for lasting increases in wettability, while the surface functional species are shorter lived. We can approximate from ageing that the increase in wettability for PCL after plasma treatment is 55-60% due to roughening and 40-45% due to surface functionalization for the plasma device investigated.

Orthopaedic tissue engineering and bone regeneration.

Orthopaedic tissue engineering combines the application of scaffold materials, cells and the release of growth factors. It has been described as the science of persuading the body to reconstitute or repair tissues that have failed to regenerate or heal spontaneously. In the case of bone regeneration 3-D scaffolds are used as a framework to guide tissue regeneration. Mesenchymal cells obtained from the patient via biopsy are grown on biomaterials in vitro and then implanted at a desired site in the patient's body. Medical implants that encourage natural tissue regeneration are generally considered more desirable than metallic implants that may need to be removed by subsequent intervention. Numerous polymeric materials, from natural and artificial sources, are under investigation as substitutes for skeletal elements such as cartilage and bone. For bone regeneration, cells (obtained mainly from bone marrow aspirate or as primary cell outgrowths from bone biopsies) can be combined with biodegradable polymeric materials and/or ceramics and absorbed growth factors so that osteoinduction is facilitated together with osteoconduction; through the creation of bioactive rather than bioinert scaffold constructs. Relatively rapid biodegradation enables advantageous filling with natural tissue while loss of polymer strength before mass is disadvantageous. Innovative solutions are required to address this and other issues such as the biocompatibility of material surfaces and the use of appropriate scaffold topography and porosity to influence bone cell gene expression.