Kah Fai Leong

3D printing of smart materials: A review on recent progresses in 4D printing

ABSTRACT Additive manufacturing (AM), commonly known as three-dimensional (3D) printing or rapid prototyping, has been introduced since the late 1980s. Although a considerable amount of progress has been made in this field, there is still a lot of research work to be done in order to overcome the various challenges remained. Recently, one of the actively researched areas lies in the additive manufacturing of smart materials and structures. Smart materials are those materials that have the ability to change their shape or properties under the influence of external stimuli. With the introduction of smart materials, the AM-fabricated components are able to alter their shape or properties over time (the 4th dimension) as a response to the applied external stimuli. Hence, this gives rise to a new term called ‘4D printing’ to include the structural reconfiguration over time. In this paper, recent major progresses in 4D printing are reviewed, including 3D printing of enhanced smart nanocomposites, shape memory alloys, shape memory polymers, actuators for soft robotics, self-evolving structures, anti-counterfeiting system, active origami and controlled sequential folding, and some results from our ongoing research. In addition, some research activities on 4D bio-printing are included, followed by discussions on the challenges, applications, research directions and future trends of 4D printing.

Revealing martensitic transformation and α/β interface evolution in electron beam melting three-dimensional-printed Ti-6Al-4V.

As an important metal three-dimensional printing technology, electron beam melting (EBM) is gaining increasing attention due to its huge potential applications in aerospace and biomedical fields. EBM processing of Ti-6Al-4V as well as its microstructure and mechanical properties were extensively investigated. However, it is still lack of quantitative studies regarding its microstructural evolution, indicative of EBM thermal process. Here, we report α′ martensitic transformation and α/β interface evolution in varied printing thicknesses of EBM-printed Ti-6Al-4V block samples by means of atom probe tomography. Quantitative chemical composition analysis suggests a general phase transformation sequence. By increasing in-fill hatched thickness, elemental partitioning ratios arise and β volume fraction is increased. Furthermore, we observe kinetic vanadium segregation and aluminum depletion at interface front and the resultant α/β interface widening phenomenon. It may give rise to an increased α/β lattice mismatch and weakened α/β interfaces, which could account for the degraded strength as printing thickness increases.

3D printing trends in building and construction industry: a review

ABSTRACT Three-dimensional (3D) printing (also known as additive manufacturing) is an advanced manufacturing process that can produce complex shape geometries automatically from a 3D computer-aided design model without any tooling, dies and fixtures. This automated manufacturing process has been applied to many diverse fields of industries today due to significant advantages of creating functional prototypes in reasonable build time with less human intervention and minimum material wastage. However, a more recent application of this technology towards the built environment seems to improve our traditional building strategies while reducing the need for human resources, high capital investments and additional formworks. Research interest in employing 3D printing for building and construction has increased exponentially in the past few years. This paper reviews the latest research trends in the discipline by analysing publications from 1997 to 2016. Some recent developments for 3D concrete printing at the Singapore Centre for 3D Printing are also discussed here. Finally, this paper gives a brief description of future work that can be done to improve both the capability and printing quality of the current systems.

Indirect fabrication of gelatin scaffolds using rapid prototyping technology

Scaffold-based tissue engineering strategies often face the problem of tissues forming only within the periphery layers of the scaffold due to mass transfer issues. In the present study, we attempt to overcome this limitation by incorporating a three-dimensional (3D) interconnected network of channels within the scaffold as part of the fabrication process so as to enhance nutrient delivery and cell migration. A scaffold material with the ability to foam was also used in conjunction with this process in order to produce highly interconnected pores within the scaffold. This article describes the developmental process of an indirect fabrication approach which involves the application of rapid prototyping (RP) technology as well as the use of a foaming scaffold material to produce highly and uniformly porous scaffolds with complex channel architectures. Finally, cytotoxicity assessment confirmed that the multiple steps involved in the fabrication process did not induce toxicity within the scaffold.

Clothing polymer fibers with well-aligned and high-aspect ratio carbon nanotubes

It is believed that the crucial step towards preparation of electrical conductive polymer-carbon nanotube (CNT) composites is dispersing CNTs with a high length-to-diameter aspect ratio in a well-aligned manner. However, this process is extremely challenging when dealing with long and entangled CNTs. Here in this study, a new approach is demonstrated to fabricate conductive polymer-CNT composite fibers without involving any dispersion process. Well-aligned CNT films were firstly drawn from CNT arrays, and then directly coated on polycaprolactone fibers to form polymer-CNT composite fibers. The conductivity of these composite fibers can be as high as 285 S m(-1) with only 2.5 wt% CNT loading, and reach 1549 S m(-1) when CNT loading is 13.4 wt%. As-prepared composite fibers also exhibit 82% retention of conductivity at a strain of 7%, and have improved mechanical properties.

Development of cryogenic prototyping for tissue engineering

A major challenge in tissue engineering has been the creation of scaffolds with controlled complex geometries. Rapid prototyping (RP) has the ability to produce complex three-dimensional structures with precise control of pore size, geometry and connectivity. In this paper, a novel technique utilising RP technology for the fabrication of tissue engineering scaffolds is presented. The main advantage of this cryogenic prototyping (CP) technique is the low operating temperatures which will allow the processing of temperature sensitive and bioactive components. Microstructure of CP Chitosan scaffolds fabricated can be controlled by processing parameters, such as the processing temperature. The macrostructure of the scaffolds is controlled by 3D computer aided design (CAD). In addition, in vitro studies with Chitosan CP scaffolds have shown that the scaffold designs are useful in promoting cell infiltration and alignment. Preliminary in vivo studies show encouraging results of cellular infiltration as well as vascularisation.

Investigation on processing of ASTM A131 Eh36 high tensile strength steel using selective laser melting

ABSTRACT In this paper, selective laser melting (SLM) technique was used to investigate the processing of EH36 high tensile strength steel commonly used in the shipbuilding applications. EH36 powder was produced according to ASTM A131 standards using gas atomisation process. SLM process parameters, including scanning speed and hatch spacing, were investigated to produce test specimens with high density. Parts were successfully built using SLM without cracks. Density tests were performed according to ASTM B962 standards. Light optical microscopy and scanning electron microscopy showed slight porosities and martensitic microstructure respectively. The study concluded that EH36 parts could be produced using SLM and this provided foundation work for the technical feasibility of fabricating high tensile strength steel components for the shipbuilding industry.

3D Bioprinting of Highly Thixotropic Alginate/Methylcellulose Hydrogel with Strong Interface Bonding

A robust alginate/methylcellulose (Alg/MC) blend hydrogel, with a strategy to improve adhesion between printed layers, has been fabricated for the first time for three-dimensional (3D) bioprinting. The optimized Alg/MC blend hydrogel exhibits a highly thixotropic property, great extrudability, and stackability. With treatment by a trisodium citrate (TSC) solution, the interfacial bonding between the printed layers is significantly improved. The TSC solution acts as a chelating agent to remove the superficial calcium ions at each layer. Post-cross-linking in a CaCl2 bath after 3D printing further enhances the adhesion strength between the layers. The key parameters affecting the interfacial strength of the Alg/MC hydrogel are found to be the concentration of TSC, the volume of TSC, and the concentration of CaCl2 in the bath. The Alg/MC hydrogel with the aid of TSC demonstrates superior printability, high stackability (150 layers can be printed), and high shape fidelity. A good cell viability of >95% is obtained for a freshly 3D-bioprinted Alg/MC construct. The novel Alg/MC hydrogel with the aid of TSC has been shown to have a great potential as an advanced 3D bioprinting material.

The use of rapid prototyping in the design of a customised ankle brace structure for ACL injury risk reduction

Rapid prototyping, or additive manufacturing, is becoming more useful in creating functional prototypes, especially when customisation is required. This paper explores the use of three-dimensional (3D) printing in designing a customised ankle brace structure for anterior cruciate ligament (ACL) injury risk reduction. A new process is proposed to obtain ankle flexion angles and the corresponding foot surface strain associated with high ACL injury risks through motion analysis. This data is used in the design of the customised ankle brace structure and printed using rapid prototyping. One customised ankle brace structure was printed and tested to demonstrate this proposed framework. The ankle flexion range of motion (ROM) was significantly reduced in the high-risk ankle positions with the ankle brace structure. Rapid prototyping could thus be used to design customised ankle brace structures and this is useful in reducing fabrication time and complexity of customisation.

Effects of foot rotation positions on knee valgus during single-leg drop landing: Implications for ACL injury risk reduction

BACKGROUND Non-contact anterior cruciate ligament (ACL) injuries commonly occur when athletes land in high risk positions such as knee valgus. The position of the foot at landing may influence the transmission of forces from the ankle to the knee. Using an experimental approach to manipulate foot rotation positions, this study aimed to provide new insights on how knee valgus during single-leg landing may be influenced by foot positions. METHODS Eleven male recreational basketball players performed single-leg drop landings from a 30-cm high platform in three foot rotation positions (toe-in, toe-forward and toe-out) at initial contact. A motion capture system and a force plate were used to measure lower extremity kinematics and kinetics. Knee valgus angles at initial contact (KVA) and maximum knee valgus moments (KVM), which were known risk factors associated with ACL injury, were measured. A one-way repeated measures Analysis of Variance was conducted (α=0.05) to compare among the three foot positions. RESULTS Foot rotation positions were found to have a significant effect on KVA (p<0.001, η2=0.66) but the difference between conditions (about 1°) was small and not clinically meaningful. There was a significant effect of foot position on KVM (p<0.001, η2=0.55), with increased moment observed in the toe-out position as compared to toe-forward (p=0.012) or toe-in positions (p=0.002). CONCLUSIONS When landing with one leg, athletes should avoid extreme toe-out foot rotation positions to minimise undesirable knee valgus loading associated with non-contact ACL injury risks.