Jianzhong Fu

Coaxial nozzle-assisted 3D bioprinting with built-in microchannels for nutrients delivery

This study offers a novel 3D bioprinting method based on hollow calcium alginate filaments by using a coaxial nozzle, in which high strength cell-laden hydrogel 3D structures with built-in microchannels can be fabricated by controlling the crosslinking time to realize fusion of adjacent hollow filaments. A 3D bioprinting system with a Z-shape platform was used to realize layer-by-layer fabrication of cell-laden hydrogel structures. Curving, straight, stretched or fractured filaments can be formed by changes to the filament extrusion speed or the platform movement speed. To print a 3D structure, we first adjusted the concentration and flow rate of the sodium alginate and calcium chloride solution in the crosslinking process to get partially crosslinked filaments. Next, a motorized XY stages with the coaxial nozzle attached was used to control adjacent hollow filament deposition in the precise location for fusion. Then the Z stage attached with a Z-shape platform moved down sequentially to print layers of structure. And the printing process always kept the top two layers fusing and the below layers solidifying. Finally, the Z stage moved down to keep the printed structure immersed in the CaCl2 solution for complete crosslinking. The mechanical properties of the resulting fused structures were investigated. High-strength structures can be formed using higher concentrations of sodium alginate solution with smaller distance between adjacent hollow filaments. In addition, cell viability of this method was investigated, and the findings show that the viability of L929 mouse fibroblasts in the hollow constructs was higher than that in alginate structures without built-in microchannels. Compared with other bioprinting methods, this study is an important technique to allow easy fabrication of lager-scale organs with built-in microchannels.

Fabrication of low cost soft tissue prostheses with the desktop 3D printer

Soft tissue prostheses such as artificial ear, eye and nose are widely used in the maxillofacial rehabilitation. In this report we demonstrate how to fabricate soft prostheses mold with a low cost desktop 3D printer. The fabrication method used is referred to as Scanning Printing Polishing Casting (SPPC). Firstly the anatomy is scanned with a 3D scanner, then a tissue casting mold is designed on computer and printed with a desktop 3D printer. Subsequently, a chemical polishing method is used to polish the casting mold by removing the staircase effect and acquiring a smooth surface. Finally, the last step is to cast medical grade silicone into the mold. After the silicone is cured, the fine soft prostheses can be removed from the mold. Utilizing the SPPC method, soft prostheses with smooth surface and complicated structure can be fabricated at a low cost. Accordingly, the total cost of fabricating ear prosthesis is about

Research on the printability of hydrogels in 3D bioprinting.

30, which is much lower than the current soft prostheses fabrication methods.

Research on optimization of the hot embossing process

As the biocompatible materials, hydrogels have been widely used in three- dimensional (3D) bioprinting/organ printing to load cell for tissue engineering. It is important to precisely control hydrogels deposition during printing the mimic organ structures. However, the printability of hydrogels about printing parameters is seldom addressed. In this paper, we systemically investigated the printability of hydrogels from printing lines (one dimensional, 1D structures) to printing lattices/films (two dimensional, 2D structures) and printing 3D structures with a special attention to the accurate printing. After a series of experiments, we discovered the relationships between the important factors such as air pressure, feedrate, or even printing distance and the printing quality of the expected structures. Dumbbell shape was observed in the lattice structures printing due to the hydrogel diffuses at the intersection. Collapses and fusion of adjacent layer would result in the error accumulation at Z direction which was an important fact that could cause printing failure. Finally, we successfully demonstrated a 3D printing hydrogel scaffold through harmonize with all the parameters. The cell viability after printing was compared with the casting and the results showed that our bioprinting method almost had no extra damage to the cells.

A robust 2D point-sequence curve offset algorithm with multiple islands for contour-parallel tool path

The hot embossing of polymer was studied to improve product quality. The finite element method (FEM) was used to analyze the embossing step, the cooling step and the demolding step with respect to product quality. The numerical simulation results show that profile precision is largely influenced by the topological structure of the mold during the embossing step. Inadequate holding time will result in low pattern fidelity. Inappropriate demolding temperature could induce a large thermal stress at the bottom of the micro pattern, while keeping imprint pressure during the cooling step will aggravate this phenomenon. Fracture, necking and pattern distortion can easily be induced by adhesion between the polymer and the mold when high aspect ratio patterns are demolded. The hot embossing process was optimized and an improved hot embossing system with an automatic demolding device was designed based on the simulation analysis. Successful fabrication of fine patterns with a high aspect ratio verified the improvements.

Rapid fabrication of paper-based microfluidic analytical devices with desktop stereolithography 3D printer

An offset algorithm is important to the contour-parallel tool path generation process. Usually, it is necessary to offset with islands. In this paper a new offset algorithm for a 2D point-sequence curve (PS-curve) with multiple islands is presented. The algorithm consists of three sub-processes, the islands bridging process, the raw offset curve generation and the global invalid loops removal. The input of the algorithm is a set of PS-curves, in which one of them is the outer profile and the others are islands. The bridging process bridges all the islands to the outer profile with the Delaunay triangulation method, forming a single linked PS-curve. With the fact that local problems are caused by intersections of adjacent bisectors, the concept of stuck circle is proposed. Based on stuck circle, local problems are fixed by updating the original profile with the proposed basic rule and append rule, so that a raw offset curve can be generated. The last process first reports all the self-intersections on the raw offset PS-curve, and then a procedure called tree analysis puts all the self-intersections into a tree. All the points between the nodes in even depth and its immediate children are collected using the collecting rule. The collected points form the valid loops, which is the output of the proposed algorithm. Each sub-process can be complete in near linear time, so the whole algorithm has a near linear time complexity. This can be proved by the examples tested in the paper.

Bioactive glass-reinforced bioceramic ink writing scaffolds: sintering, microstructure and mechanical behavior

In this study, we developed a novel and facile method for fabricating paper-based microfluidic analytical devices (μPADs) with dynamic mask photo curing (DMPC), generated by a desktop stereolithography (SL) three-dimensional printer (3DP). First, we immersed the filter paper in ultraviolet (UV) resin to cover it evenly. Next, we exposed it to UV-light through a dynamic mask of the negative channel pattern. After curing, the UV-exposed regions become highly hydrophobic, creating hydrophobic barriers. Finally, we washed the uncured resin with anhydrous alcohol and fine μPADs were obtained. The resolution of the fabricated hydrophilic channels was 367 ± 20 μm, with a between-channel hydrophobic barrier of 400 ± 21 μm. To verify this methods performance, we fabricated μPADs with DMPC for quantitative analysis of nitrite ion. This new method represents a leap forward in terms of time saved. Since all hydrophobic barriers are cured at a time, the fabrication process can be completed in only two minutes, no matter how complex the patterns are. Compared to the widely used fabrication method of μPADs, wax printing, DMPC provides an alternative way to fabricate μPAD with different hydrophobic barriers materials, which provides the possibility of designing different μPADs according to the application environments.

A generic uniform scallop tool path generation method for five-axis machining of freeform surface ☆

The densification of pore struts in bioceramic scaffolds is important for structure stability and strength reliability. An advantage of ceramic ink writing is the precise control over the microstructure and macroarchitecture. However, the use of organic binder in such ink writing process would heavily affect the densification of ceramic struts and sacrifice the mechanical strength of porous scaffolds after sintering. This study presents a low-melt-point bioactive glass (BG)-assisted sintering strategy to overcome the main limitations of direct ink writing (extrusion-based three-dimensional printing) and to produce high-strength calcium silicate (CSi) bioceramic scaffolds. The 1% BG-added CSi (CSi-BG1) scaffolds with rectangular pore morphology sintered at 1080 °C have a very small BG content, readily induce apatite formation, and show appreciable linear shrinkage (∼21%), which is consistent with the composite scaffolds with less or more BG contents sintered at either the same or a higher temperature. These CSi-BG1 scaffolds also possess a high elastic modulus (∼350 MPa) and appreciable compressive strength (∼48 MPa), and show significant strength enhancement after exposure to simulated body fluid-a performance markedly superior to those of pure CSi scaffolds. Particularly, the honeycomb-pore CSi-BG1 scaffolds show markedly higher compressive strength (∼88 MPa) than the scaffolds with rectangular, parallelogram, and Archimedean chord pore structures. It is suggested that this approach can potentially facilitate the translation of ceramic ink writing and BG-assisted sintering of bioceramic scaffold technologies to the in situ bone repair.

A fine-interpolation-based parametric interpolation method with a novel real-time look-ahead algorithm

Abstract In this paper, a generic uniform scallop tool path generation method for five-axis machining is presented. Unlike the conventional methods which are based on the local surface geometry assumptions, this method is inspired by cutting simulation. Initially, the designed surface is planted with dense grasses. If a cutter is put onto the surface, the affected grasses will be cut short. All the affected grasses form a grass ring on the surface. When the cutter moves along the previous tool path, the envelope of the grass rings will form a machining band. Based on the machining band, cutter contact points can be found on the surface to ensure that the cutting edge touches exactly on the side of the band. These cutter contact points are fitted to construct the next tool path. In this way, all the tool paths can be generated recursively. An optimization is also developed to improve the computing efficiency of the path generation process. The proposed uniform scallop tool path generation method is generic. It can be popularized to (1) any kind of end mill with various sizes, (2) any kind of parametric surface and (3) directional- or contour-parallel tool path topologies. Another salient feature of this method is that it is free of local surface geometry assumptions, so the obtained tool paths are more precise. The proposed method is implemented and evaluated with several freeform surface examples. The feasibility of the method is also verified by actual cutting experiment.

Intelligent fault diagnosis using rough set method and evidence theory for NC machine tools

Parametric interpolation is presently supported by majority of CNC systems because of its various advantages over traditional linear/circular interpolation. Two stages (i.e. rough interpolation and fine interpolation) involved in parametric interpolation are complementary to each other in terms of affecting machining quality significantly. So far much work has been conducted to improve the machining process with various rough interpolation adjustments, while with little research on fine interpolation. To further alleviate the feedrate jump between two adjacent rough interpolation periods, a fine interpolating strategy implemented within one rough interpolation period can be utilized to make the feedrate alteration comparatively smooth. Meanwhile, an arc is adopted to substitute the linear path to reduce the chord errors caused by rough interpolation. Besides, as one of the major difficulties of parametric interpolation is the feedrate determination concerning a wide variety of technical parameters, a real-time look-ahead feedrate generation method which can determine the decelerating position rapidly and accurately is proposed in this paper. The look-ahead approach can generate the feedrate profile to satisfy the geometrical constraints and kinematical characteristics determined by machine tools. Finally, the proposed parametric interpolation method is performed in an open architecture CNC platform to machine parametric curves. The results are satisfactory and are able to verify the robustness and effectiveness of the proposed algorithm.