Powder Bed Fusion 3D Printing in Precision Manufacturing for Biomedical Applications: A Comprehensive Review.

Precision manufacturing requirements are the key to ensuring the quality and reliability of biomedical implants. The powder bed fusion (PBF) technique offers a promising solution, enabling the creation of complex, patient-specific implants with a high degree of precision. This technology is revolutionizing the biomedical industry, paving the way for a new era of personalized medicine. This review explores and details powder bed fusion 3D printing and its application in the biomedical field. It begins with an introduction to the powder bed fusion 3D-printing technology and its various classifications. Later, it analyzes the numerous fields in which powder bed fusion 3D printing has been successfully deployed where precision components are required, including the fabrication of personalized implants and scaffolds for tissue engineering. This review also discusses the potential advantages and limitations for using the powder bed fusion 3D-printing technology in terms of precision, customization, and cost effectiveness. In addition, it highlights the current challenges and prospects of the powder bed fusion 3D-printing technology. This work offers valuable insights for researchers engaged in the field, aiming to contribute to the advancement of the powder bed fusion 3D-printing technology in the context of precision manufacturing for biomedical applications.

Effect of Cyrtostachys renda Fiber Loading on the Mechanical, Morphology, and Flammability Properties of Multi-Walled Carbon Nanotubes/Phenolic Bio-Composites.

This research focuses on evaluating the effect of Cyrtostachys renda (CR) fiber and the impact of adding multi-walled carbon nanotubes (MWCNT) on the morphological, physical, mechanical, and flammability properties of phenolic composites. MWCNT were supplemented with phenolic resin through a dry dispersion ball milling method. Composites were fabricated by incorporating CR fiber in 0.5 wt.% MWCNT-phenolic matrix by hot pressing. Nevertheless, the void content, higher water absorption, and thickness swelling increased with fiber loading to the MWCNT/phenolic composites. The presence of MWCNT in phenolic enhanced the tensile, flexural, and impact strength by as much as 18%, 8%, and 8%, respectively, compared to pristine phenolic. The addition of CR fiber, however, strengthened MWCNT-phenolic composites, improving the tensile, flexural, and impact strength by as much as 16%, 16%, and 266%, respectively, for 50 wt.% loading of CR fiber. The CR fiber may adhere properly to the matrix, indicating that there is a strong interface between fiber and MWCNT-phenolic resin. UL-94 horizontal and limiting oxygen index (LOI) results indicated that all composite materials are in the category of self-extinguishing. Based on the technique for order preference by similarity to the ideal solution (TOPSIS) technique, 50 wt.% CR fiber-reinforced MWCNT-phenolic composite was chosen as the optimal composite for mechanical and flammability properties. This bio-based eco-friendly composite has the potential to be used as an aircraft interior component.

Testing of Silicon Rubber/Montmorillonite Nanocomposite for Mechanical and Tribological Performance.

Nanocomposite made by blending nano-montmorillonite (MMT) and Silicon Rubber (SR) for mechanical and tribological performance is explored in this work. Different configurations of MMT/SR nanocomposite, with 0, 0.5, 2 and 5 wt % of MMT are manufactured by two roll mixing methods. Noticeable improvement in the mechanical and tribological performance is observed, which is also justified by a morphological study of fractured and wear surfaces through SEM. Two percent of MMT loading is found to be the optimum content that shows excellent performance compared to other compositions. The performance improvement can be linked to the good interfacial interaction between the MMT and SR. Statistical modeling through ANOVA is carried out for tribological performance, which reveals the influence of load on the coefficient of friction (COF) and the influence of sliding distance on the wear rate.

Physical, Mechanical, and Morphological Properties of Hybrid Cyrtostachys renda/Kenaf Fiber Reinforced with Multi-Walled Carbon Nanotubes (MWCNT)-Phenolic Composites.

Adequate awareness of sustainable materials and eco-legislation have inspired researchers to identify alternative sustainable and green composites for synthetic fiber-reinforced polymer composites in the automotive and aircraft industries. This research focused on investigating the physical, mechanical, and morphological properties of different hybrid Cyrtostachys renda (CR)/kenaf fiber (K) (10C:0K, 7C:3K, 5C:5K, 3C:7K, 0C:10K) reinforced with 0.5 wt% MWCNT-phenolic composites. We incorporated 0.5 wt% of MWCNT into phenolic resin (powder) using a ball milling process for 25 h to achieve homogeneous distribution. The results revealed that CR fiber composites showed higher voids content (12.23%) than pure kenaf fiber composites (6.57%). CR fiber phenolic composite was more stable to the swelling tendency, resulting in the lowest percentage of swelling rate (4.11%) compared to kenaf composite (5.29%). The addition of kenaf fiber into CR composites had improved the tensile, flexural, and impact properties. The highest tensile and flexural properties were found for weight fraction of CR and kenaf fiber at 5C:5K (47.96 MPa) and 3C:7K (90.89 MPa) composites, respectively. In contrast, the highest impact properties were obtained for 0C:10K composites (9.56 kJ/m2). Based on the FE-SEM image, the CR fiber lumen was larger in comparison to kenaf fiber. The lumen of CR fiber was attributed to higher void and water absorption, lower mechanical properties compared to kenaf fiber. 5C:5K composite was selected as an optimal hybrid composite, based on the TOPSIS method. This hybrid composite can be used as an interior component (non-load-bearing structures) in the aviation and automotive sectors.

Low-Velocity Impact Analysis of Pineapple Leaf Fiber (PALF) Hybrid Composites.

The low-velocity impact behaviour of pineapple leaf fiber, PALF reinforce epoxy composite (P), PALF hybrid (GPG), and four-layer woven glass fiber (GGGG) composite was investigated. As for post-impact analysis, the damage evaluation was assessed through photographic images and X-ray computed tomography, using CT scan techniques. The key findings from this study are that a positive hybrid effect of PALF as a reinforcement was seen where the GPG shows the delayed time taken for damage initiation and propagation through the whole sample compared to GGGG. This clearly shows that the addition of fibers does have comparable composite properties with a fully synthetic composite. Through the visual inspection captured by photographic image, the presence of woven fiber glass mat in GPG presents a different damage mode compared to P. Moreover, CT scan results show extended internal damage at the cross-section of all impacted composite.

Investigations on the Mechanical Properties of Glass Fiber/Sisal Fiber/Chitosan Reinforced Hybrid Polymer Sandwich Composite Scaffolds for Bone Fracture Fixation Applications.

This study aims to explore the mechanical properties of hybrid glass fiber (GF)/sisal fiber (SF)/chitosan (CTS) composite material for orthopedic long bone plate applications. The GF/SF/CTS hybrid composite possesses a unique sandwich structure and comprises GF/CTS/epoxy as the external layers and SF/CTS/epoxy as the inner layers. The composite plate resembles the human bone structure (spongy internal cancellous matrix and rigid external cortical). The mechanical properties of the prepared hybrid sandwich composites samples were evaluated using tensile, flexural, micro hardness, and compression tests. The scanning electron microscopic (SEM) images were studied to analyze the failure mechanism of these composite samples. Besides, contact angle (CA) and water absorption tests were conducted using the sessile drop method to examine the wettability properties of the SF/CTS/epoxy and GF/SF/CTS/epoxy composites. Additionally, the porosity of the GF/SF/CTS composite scaffold samples were determined by using the ethanol infiltration method. The mechanical test results show that the GF/SF/CTS hybrid composites exhibit the bending strength of 343 MPa, ultimate tensile strength of 146 MPa, and compressive strength of 380 MPa with higher Young's modulus in the bending tests (21.56 GPa) compared to the tensile (6646 MPa) and compressive modulus (2046 MPa). Wettability study results reveal that the GF/SF/CTS composite scaffolds were hydrophobic (CA = 92.41° ± 1.71°) with less water absorption of 3.436% compared to the SF/CTS composites (6.953%). The SF/CTS composites show a hydrophilic character (CA = 54.28° ± 3.06°). The experimental tests prove that the GF/SF/CTS hybrid composite can be used for orthopedic bone fracture plate applications in future.

A Review on the Kenaf/Glass Hybrid Composites with Limitations on Mechanical and Low Velocity Impact Properties.

Environmental awareness and trends to develop sustainable resources have directed much research attention towards kenaf fibre as an alternative reinforcement in composite manufacturing. Numerous studies have been conducted on kenaf and its hybrid composites. Most studies were conducted on kenaf/glass hybrid composites compared to other kenaf/synthetic hybrid composites. Similar with other materials, mechanical properties were the fundamental knowledge identified by the researcher. Limited studies conducted on other properties have restricted the use of kenaf composites to non-structural applications. To extend the potential of kenaf composites to automotive exterior or other critical applications, studies on impact properties can be a valuable contribution in the material field. This review discusses the mechanical and low velocity impact properties of kenaf/glass hybrid composites reported previously. Percentage loading of fibre, the angle of orientation in woven fibres and the chemical treatment applied to the fibre before compounding are the three major parameters that affect the mechanical and impact properties of the composites. This review provides insights into the mechanical and impact properties of kenaf/glass hybrid composites for future research.

Experimental Evaluation of Low Velocity Impact Properties and Damage Progression on Bamboo/Glass Hybrid Composites Subjected to Different Impact Energy Levels.

Six impact energy values, ranging from 2.5 J to 10 J, were applied to study the impact properties of neat epoxy and bamboo composites, while six impact energy values, ranging from 10 J to 35 J, were applied on bamboo/glass hybrid composites. Woven glass fibre was embedded at the outermost top and bottom layer of bamboo powder-filled epoxy composites, producing sandwich structured hybrid composites through lay-up and molding techniques. A drop weight impact test was performed to study the impact properties. A peak force analysis showed that neat epoxy has the stiffest projectile for targeting interaction, while inconsistent peak force data was collected for the non-hybrid composites. The non-hybrid composites could withstand up to 10 J, while the hybrid composites showed a total failure at 35 J. It can be concluded that increasing the filler loading lessened the severity of damages in non-hybrid composites, while introducing the woven glass fibre could slow down the penetration of the impactor, thus lowering the chances of a total failure of the composites.

A review on the orthotics and prosthetics and the potential of kenaf composites as alternative materials for ankle-foot orthosis.

Since ancient Egypt, orthosis was generally made from wood and then later replaced with metal and leather which are either heavy, bulky, or thick decreasing comfort among the wearers. After the age of revolution, the manufacturing of products using plastics and carbon composites started to spread due to its low cost and form-fitting feature whereas carbon composite were due to its high strength/stiffness to weight ratio. Both plastic and carbon composite has been widely applied into medical devices such as the orthosis and prosthesis. However, carbon composite is also quite expensive, making it the less likely material to be used as an Ankle-Foot Orthosis (AFO) material whereas plastics has low strength. Kenaf composite has a high potential in replacing all the current materials due to its flexibility in controlling the strength to weight ratio properties, cost-effectiveness, abundance of raw materials, and biocompatibility. The aim of this review paper is to discuss on the possibility of using kenaf composite as an alternative material to fabricate orthotics and prosthetics. The discussion will be on the development of orthosis since ancient Egypt until current era, the existing AFO materials, the problems caused by these materials, and the possibility of using a Kenaf fiber composite as a replacement of the current materials. The results show that Kenaf composite has the potential to be used for fabricating an AFO due to its tensile strength which is almost similar to polypropylene's (PP) tensile strength, and the cheap raw material compared to other type of materials.