Timothy J. Horn

Overview of Current Additive Manufacturing Technologies and Selected Applications

Three-dimensional printing or rapid prototyping are processes by which components are fabricated directly from computer models by selectively curing, depositing or consolidating materials in successive layers. These technologies have traditionally been limited to the fabrication of models suitable for product visualization but, over the past decade, have quickly developed into a new paradigm called additive manufacturing. We are now beginning to see additive manufacturing used for the fabrication of a range of functional end use components. In this review, we briefly discuss the evolution of additive manufacturing from its roots in accelerating product development to its proliferation into a variety of fields. Here, we focus on some of the key technologies that are advancing additive manufacturing and present some state of the art applications.

Multi-sample Arabidopsis Growth and Imaging Chamber (MAGIC) for long term imaging in the ZEISS Lightsheet Z.1

Time-course imaging experiments on live organisms are critical for understanding the dynamics of growth and development. Light-sheet microscopy has advanced the field of long-term imaging of live specimens by significantly reducing photo-toxicity and allowing fast acquisition of three-dimensional data over time. However, current light-sheet technology does not allow the imaging of multiple plant specimens in parallel. To achieve higher throughput, we have developed a Multi-sample Arabidopsis Growth and Imaging Chamber (MAGIC) that provides near-physiological imaging conditions and allows high-throughput time-course imaging experiments in the ZEISS Lightsheet Z.1. Here, we illustrate MAGICs imaging capabilities by following cell divisions, as an indicator of plant growth and development, over prolonged time periods. To automatically quantify the number of cell divisions in long-term experiments, we present a FIJI-based image processing pipeline. We demonstrate that plants imaged with our chamber undergo cell divisions for >16 times longer than those with the glass capillary system supplied by the ZEISS Z1.

Development and validation of a canine radius replica for mechanical testing of orthopedic implants.

OBJECTIVE To design and fabricate fiberglass-reinforced composite (FRC) replicas of a canine radius and compare their mechanical properties with those of radii from dog cadavers. SAMPLE Replicas based on 3 FRC formulations with 33%, 50%, or 60% short-length discontinuous fiberglass by weight (7 replicas/group) and 5 radii from large (> 30-kg) dog cadavers. PROCEDURES Bones and FRC replicas underwent nondestructive mechanical testing including 4-point bending, axial loading, and torsion and destructive testing to failure during 4-point bending. Axial, internal and external torsional, and bending stiffnesses were calculated. Axial pullout loads for bone screws placed in the replicas and cadaveric radii were also assessed. RESULTS Axial, internal and external torsional, and 4-point bending stiffnesses of FRC replicas increased significantly with increasing fiberglass content. The 4-point bending stiffness of 33% and 50% FRC replicas and axial and internal torsional stiffnesses of 33% FRC replicas were equivalent to the cadaveric bone stiffnesses. Ultimate 4-point bending loads did not differ significantly between FRC replicas and bones. Ultimate screw pullout loads did not differ significantly between 33% or 50% FRC replicas and bones. Mechanical property variability (coefficient of variation) of cadaveric radii was approximately 2 to 19 times that of FRC replicas, depending on loading protocols. CONCLUSIONS AND CLINICAL RELEVANCE Within the range of properties tested, FRC replicas had mechanical properties equivalent to and mechanical property variability less than those of radii from dog cadavers. Results indicated that FRC replicas may be a useful alternative to cadaveric bones for biomechanical testing of canine bone constructs.

Development of a patient-specific bone analog for the biomechanical evaluation of custom implants

Purpose – The aim of this study is to describe an improved experimental substrate for the mechanical testing of patient-specific implants fabricated using direct metal additive manufacturing processes. This method reduces variability and sample size requirements and addresses the importance of geometry at the bone/implant interface. Design/methodology/approach – Short-fiber glass/resin materials for cortical bone and polyurethane foam materials for cancellous bone were evaluated using standard tensile coupons. A method for fabricating bone analogs with patient-specific geometries using rapid tooling is presented. Bone analogs of a canine radius were fabricated and compared to cadaveric specimens in several biomechanical tests as validation. Findings – The analog materials exhibit a tensile modulus that falls within the range of expected values for cortical and cancellous bone. The tensile properties of the cortical bone analog vary with fiber loading. The canine radius models exhibited similar mechanical ...