Carl Diver

Sequential laser and EDM micro-drilling for next generation fuel injection nozzle manufacture

High quality holes of diameters less than 145 μm are required for the manufacture of next generation diesel fuel injection nozzles for improved combustion efficiency and reduction of emission to the environment. The current practice of using electro-discharge machining (EDM) drilling of fuel injection nozzles is limited in terms of the hole size it can produce effectively and the length of time needed to drill. In addition, the tooling cost is high. This paper reports on an investigation into a sequential laser and EDM micro-drilling technique for the manufacture of next generation fuel injection nozzles. A laser-drilled pilot hole is rimmed out by EDM drilling. It was found that this hybrid process has eliminated the problems of recast and heat affected zones typically associated with the laser drilling process. The new process has enabled a 70% reduction in total drilling time compared to standard EDM drilling as less material is removed by the EDM. The quality of the holes is as good as direct EDM drilling, thus eliminating the need for re-certification of the drilling process. Various combinations of laser/EDM drilling conditions have been examined. Optimum diameters for the pilot hole and the EDM electrode have been identified for a particular diameter of fuel injection nozzle, giving the minimum total drilling time and the best quality holes. A special system was designed to enable the alignment of nozzles to be controlled to within ± 20 μm. The technique has enabled valuable cost savings and increase in production capacity for next generation fuel injection nozzle manufacture.

Enhancing the Hydrophilicity and Cell Attachment of 3D Printed PCL/Graphene Scaffolds for Bone Tissue Engineering

Scaffolds are physical substrates for cell attachment, proliferation, and differentiation, ultimately leading to the regeneration of tissues. They must be designed according to specific biomechanical requirements, i.e., certain standards in terms of mechanical properties, surface characteristics, porosity, degradability, and biocompatibility. The optimal design of a scaffold for a specific tissue strongly depends on both materials and manufacturing processes, as well as surface treatment. Polymeric scaffolds reinforced with electro-active particles could play a key role in tissue engineering by modulating cell proliferation and differentiation. This paper investigates the use of an extrusion-based additive manufacturing system to produce poly(ε-caprolactone) (PCL)/pristine graphene scaffolds for bone tissue applications and the influence of chemical surface modification on their biological behaviour. Scaffolds with the same architecture but different concentrations of pristine graphene were evaluated from surface property and biological points of view. Results show that the addition of pristine graphene had a positive impact on cell viability and proliferation, and that surface modification leads to improved cell response.

Metallic bone fixation implants: a novel design approach for reducing the stress shielding phenomenon

ABSTRACT Fixation devices are commonly used for bone fracture treatments. These implants are made of biocompatible materials such as stainless steel, cobalt, titanium and its alloys (e.g. CoCrMo and Ti-6Al-4V). However, metallic medical implants present higher stiffness compared to bone, contributing to the stress shielding phenomena compromising bone integrity. This paper explores the use of topology optimization to create novel bone fixation designs with reduced material volumes. Results show that for certain levels of volume reductions, which depends on the load condition, it is possible to obtain designs that minimise the stress shielding phenomena.

Polymer-Ceramic Composite Scaffolds: The Effect of Hydroxyapatite and β-tri-Calcium Phosphate

The design of bioactive scaffolds with improved mechanical and biological properties is an important topic of research. This paper investigates the use of polymer-ceramic composite scaffolds for bone tissue engineering. Different ceramic materials (hydroxyapatite (HA) and β-tri-calcium phosphate (TCP)) were mixed with poly-ε-caprolactone (PCL). Scaffolds with different material compositions were produced using an extrusion-based additive manufacturing system. The produced scaffolds were physically and chemically assessed, considering mechanical, wettability, scanning electron microscopy and thermal gravimetric tests. Cell viability, attachment and proliferation tests were performed using human adipose derived stem cells (hADSCs). Results show that scaffolds containing HA present better biological properties and TCP scaffolds present improved mechanical properties. It was also possible to observe that the addition of ceramic particles had no effect on the wettability of the scaffolds.