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Register a new userAdditive Manufacturing Approaches for Hydroxyapatite-Reinforced Composites
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Additive manufacturing (AM) techniques have gained interest in the tissue engineering field thanks to their versatility and unique possibilities of producing constructs with complex macroscopic geometries and defined patterns. Recently, composite materials - namely heterogeneous biomaterials identified as continuous phase (matrix) and reinforcement (filler) - have been proposed as inks that can be processed by AM to obtain scaffolds with improved biomimetic and bioactive properties. Significant efforts have been dedicated to hydroxyapatite (HA)-reinforced composites, especially targeting bone tissue engineering, thanks to the chemical similarities of HA with respect to mineral components of native mineralized tissues. Here we review applications of AM techniques to process HA-reinforced composites and biocomposites for the production of scaffolds with biological matrices, including cellular tissues. The primary outcomes of recent investigations in terms of morphological, structural, and in vitro and in vivo biological properties of the materials are discussed. We classify the approaches based on the nature of the matrices employed to embed the HA reinforcements and produce the tissue substitutes and report a critical discussion on the presented state of the art as well as the future perspectives, to offer a comprehensive picture of the strategies investigated as well as challenges in this emerging field.
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A thick electrode with high areal capacity has been developed as a strategy for high-energy-density lithium-ion batteries, but thick electrodes have difficulties in manufacturing and limitations in ion transport. Here, we reported a new manufacturing approach for ultra-thick electrode with aligned structure, called structure electrode additive manufacturing or SEAM, which aligns active materials to the through-thicknesses direction of electrodes using shear flow and a designed printing path. The ultra-thick electrodes with high loading of active materials, low tortuous structure, and good structure stability resulting from a simple and scalable SEAM lead to rapid ion transport and fast electrolyte infusion, delivering a higher areal capacity than slurry-casted thick electrodes. SEAM shows strengths in design flexibility and scalability, which allows the production of practical high energy/power density structure electrodes.
In the industrial practice, additive manufacturing processes are often followed by post-processing operations such as subtractive machining, milling, etc. to achieve the desired surface quality and dimensional accuracy. Hence, a given part must be 3D printed with extra material to enable such finishing phase. This combined additive/subtractive technique can be optimized to reduce manufacturing costs by saving printing time and reducing material and energy usage. In this work, a numerical methodology based on parametric shape optimization is proposed for optimizing the thickness of the extra material, allowing for minimal machining operations while ensuring the finishing requirements. Moreover, the proposed approach is complemented by a novel algorithm for generating inner structures leading to reduced distortion and improved weight reduction. The computational effort induced by classical constrained optimization methods is alleviated by replacing both the objective and constraint functions by their sparse-grid surrogates. Numerical results showcase the effectiveness of the proposed approach.
Recent advances in the understanding and control of quantum technologies, such as those based on cold atoms, have resulted in devices with extraordinary metrological sensitivities. To realise this potential outside of a lab environment the size, weight and power consumption need to be reduced. Here we demonstrate the use of laser powder bed fusion, an additive manufacturing technique, as a production technique for the components that make up quantum sensors. As a demonstration we have constructed two key components using additive manufacturing, namely magnetic shielding and vacuum chambers. The initial prototypes for magnetic shields show shielding factors within a factor of 3 of conventional approaches. The vacuum demonstrator device shows that 3D-printed titanium structures are suitable for use as vacuum chambers, with the test system reaching base pressures of $5 pm 0.5 times 10^{-10}$ mbar. These demonstrations show considerable promise for the use of additive manufacturing for cold atom based quantum technologies, in future enabling improved integrated structures, allowing for the reduction in size, weight and assembly complexity.
Multi-axis additive manufacturing enables high flexibility of material deposition along dynamically varied directions. The Cartesian motion platforms of these machines include three parallel axes and two rotational axes. Singularity on rotational axes is a critical issue to be tackled in motion planning for ensuring high quality of manufacturing results. The highly nonlinear mapping in the singular region can convert a smooth toolpath with uniformly sampled waypoints defined in the model coordinate system into a highly discontinuous motion in the machine coordinate system, which leads to over-extrusion / under-extrusion of materials in filament-based additive manufacturing. The problem is challenging as both the maximal and the minimal speeds at the tip of a printer head must be controlled in motion. Moreover, collision may occur when sampling-based collision avoidance is employed. In this paper, we present a motion planning method to support the manufacturing realization of designed toolpaths for multi-axis additive manufacturing. Problems of singularity and collision are considered in an integrated manner to improve the motion therefore the quality of fabrication.
The future of space exploration missions will rely on technologies increasing their endurance and self-sufficiency, including for manufacturing objects on-demand. We propose a process for handling and additively manufacturing powders that functions independently of the gravitational environment and with no restriction on feedstock powder flowability. Based on a specific sequence of boundary loads applied to the granular packing, powder is transported to the printing zone, homogenized and put under compression to increase the density of the final part. The powder deposition process is validated by simulations that show the homogeneity and density of deposition to be insensitive to gravity and cohesion forces within the DEM model. We further provide an experimental proof of concept of the process by successfully 3D printing parts on-ground and in weightlessness, on parabolic flight. Powders exhibiting high and low flowability are used as model feedstock material to demonstrate the versatility of the process, opening the way for additive manufacturing of recycled material.
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