Effect of Layer Thickness and Heat Treatment on Microstructure and Mechanical Properties of Alloy 625 Manufactured by Electron Beam Powder Bed Fusion.

This research program investigated the effects of layer thickness (50 µm and 100 µm) on the microstructure and mechanical properties of electron beam powder bed fusion (EBPBF) additive manufacturing of Inconel 625 alloy. The as-built 50 µm and 100 µm layer thickness components were also heat treated at temperatures above 1100 °C which produced a recrystallized grain structure containing annealing twins in the 50 µm layer thickness components, and a duplex grain structure consisting of islands of very small equiaxed grains dispersed in a recrystallized, large-grain structure containing annealing twins. The heat-treated components of the microstructures and mechanical properties were compared with the as-built components in both the build direction (vertical) and perpendicular (horizontal) to the build direction.

Investigation of Microstructure and Mechanical Properties for Ti-6Al-4V Alloy Parts Produced Using Non-Spherical Precursor Powder by Laser Powder Bed Fusion.

An unmodified, non-spherical, hydride-dehydride (HDH) Ti-6Al-4V powder having a substantial economic advantage over spherical, atomized Ti-6Al-4V alloy powder was used to fabricate a range of test components and aerospace-related products utilizing laser beam powder-bed fusion processing. The as-built products, utilizing optimized processing parameters, had a Rockwell-C scale (HRC) hardness of 44.6.

Development and Evaluation of an Automated Manual Resuscitator-Based Emergency Ventilator-Alternative.

Mass casualty incidents such as those that are being experienced during the novel coronavirus disease (COVID-19) pandemic can overwhelm local healthcare systems, where the number of casualties exceeds local resources and capabilities in a short period of time. The influx of patients with lung function deterioration as a result of COVID-19 has strained traditional ventilator supplies. To bridge the gap during ventilator shortages and to help clinicians triage patients, manual resuscitator devices can be used to deliver respirations to a patient requiring breathing support.

Effects of Postprocess Hot Isostatic Pressing Treatments on the Mechanical Performance of EBM Fabricated TI-6Al-2Sn-4Zr-2Mo.

An essentially fully acicular alpha-prime martensite within an equiaxed grain structure was produced in an Electron Beam Melting (EBM)-fabricated Ti-6Al-2Sn-4Zr-2Mo (Ti6242) alloy using two different Arcam EBM machines: An A2X system employing tungsten filament thermionic electron emission, and a Q20 system employing LaB6 thermionic electron emission. Post-process Hot Isostatic Pressing (HIP) treatment for 2 h at 850, 950, and 1050 °C resulted in grain refinement and equiaxed grain growth along with alpha-prime martensite decomposition to form an intragranular mixture of acicular martensite and alpha at 850 °C, and acicular alpha phase at 950 and 150 °C, often exhibiting a Widmanstätten (basketweave) structure. The corresponding tensile yield stress and ultimate tensile strength (UTS) associated with the grain growth and acicular alpha evolution decreased from ~1 and ~1.

Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts with Embedded Wires for High Current-Carrying Applications.

Fabrication of parts exhibiting multi-functionality has recently been complemented by hybrid polymer extrusion additive manufacturing in combination with wire embedding technology. While much mechanical characterization has been performed on parts produced with fused deposition modeling, limited characterization has been performed when combined electrical and thermal loads are applied to 3D printed multi-material parts. As such, this work describes the design, fabrication, and testing of 3D printed thermoplastic coupons containing embedded copper wires that carried current.

Effect of headless compression screw on construct stability for centre of rotation and angulation-based levelling osteotomy. Biomechanical testing in flexion and torsion.

Objective: To compare the biomechanical properties of bone and implant constructs when used for the centre of rotation and angulation (CORA) based levelling osteotomy, with and without implantation of a trans-osteotomy headless compression screw tested under three-point flexural and torsional forces; thereby determining the contribution of a trans-osteotomy headless compression screw with regards to stability of the construct.

Methods: Experimental biomechanical study utilizing 12 pairs of cadaveric canine tibias. Using the CORA based levelling osteotomy (CBLO) procedure, the osteotomy was stabilized with either a standard non-locking CBLO bone plate augmented with a headless compression screw (HCS) or a CBLO bone plate alone.

Multiprocess 3D printing for increasing component functionality.

Layer-by-layer deposition of materials to manufacture parts-better known as three-dimensional (3D) printing or additive manufacturing-has been flourishing as a fabrication process in the past several years and now can create complex geometries for use as models, assembly fixtures, and production molds. Increasing interest has focused on the use of this technology for direct manufacturing of production parts; however, it remains generally limited to single-material fabrication, which can limit the end-use functionality of the fabricated structures. The next generation of 3D printing will entail not only the integration of dissimilar materials but the embedding of active components in order to deliver functionality that was not possible previously.

Microstereolithography and characterization of poly(propylene fumarate)-based drug-loaded microneedle arrays.

Drug-loaded microneedle arrays for transdermal delivery of a chemotherapeutic drug were fabricated using multi-material microstereolithography (μSL). These arrays consisted of twenty-five poly(propylene fumarate) (PPF) microneedles, which were precisely orientated on the same polymeric substrate. To control the viscosity and improve the mechanical properties of the PPF, diethyl fumarate (DEF) was mixed with the polymer.

Single-lumen and multi-lumen poly(ethylene glycol) nerve conduits fabricated by stereolithography for peripheral nerve regeneration in vivo.

Background: The use of nerve conduits to facilitate nerve regrowth after peripheral nerve injury is limited to defects less than 3 cm. The purpose of this study is to determine the capability of novel single and multi-lumen poly(ethylene glycol) (PEG) conduits manufactured by stereolithography to promote peripheral nerve regeneration.

Materials And Methods: Eight Sprague Dawley rats with sharp transection injuries of the sciatic nerve were randomly assigned to receive single-lumen or multi-lumen PEG conduits to bridge a 10-mm gap.

Next generation orthopaedic implants by additive manufacturing using electron beam melting.

This paper presents some examples of knee and hip implant components containing porous structures and fabricated in monolithic forms utilizing electron beam melting (EBM). In addition, utilizing stiffness or relative stiffness versus relative density design plots for open-cellular structures (mesh and foam components) of Ti-6Al-4V and Co-29Cr-6Mo alloy fabricated by EBM, it is demonstrated that stiffness-compatible implants can be fabricated for optimal stress shielding for bone regimes as well as bone cell ingrowth. Implications for the fabrication of patient-specific, monolithic, multifunctional orthopaedic implants using EBM are described along with microstructures and mechanical properties characteristic of both Ti-6Al-4V and Co-29Cr-6Mo alloy prototypes, including both solid and open-cellular prototypes manufactured by additive manufacturing (AM) using EBM.

Compression force and pullout strength comparison of bioabsorbable implants for osteochondral lesion fixation.

We conducted a study to characterize compression forces and pullout strengths of 4 commercially available bioabsorbable nails and screws in a synthetic bone model. A piezoelectric sensor was used to measure peak compression forces, and a material testing machine was used to measure maximum pullout strengths. The strongest compression force was found for SmartScrew (12.

Microstructural and Process Characterization of Conductive Traces Printed from Ag Particulate Inks.

Conductive inks are key enablers for the use of printing techniques in the fabrication of electronic systems. Focus on the understanding of aspects controlling the electrical performance of conductive ink is paramount. A comparison was made between microparticle Ag inks and an Ag nanoparticle ink.

In vitro validation of finite-element model of AAA hemodynamics incorporating realistic outlet boundary conditions.

The purpose of this study is to validate numerical simulations of flow and pressure in an abdominal aortic aneurysm (AAA) using phase-contrast magnetic resonance imaging (PCMRI) and an in vitro phantom under physiological flow and pressure conditions. We constructed a two-outlet physical flow phantom based on patient imaging data of an AAA and developed a physical Windkessel model to use as outlet boundary conditions. We then acquired PCMRI data in the phantom while it operated under conditions mimicking a resting and a light exercise physiological state.

In vitro validation of finite element analysis of blood flow in deformable models.

The purpose of this article is to validate numerical simulations of flow and pressure incorporating deformable walls using in vitro flow phantoms under physiological flow and pressure conditions. We constructed two deformable flow phantoms mimicking a normal and a restricted thoracic aorta, and used a Windkessel model at the outlet boundary. We acquired flow and pressure data in the phantom while it operated under physiological conditions.

Fabrication of Off-the-Shelf Multilumen Poly(Ethylene Glycol) Nerve Guidance Conduits Using Stereolithography.

A manufacturing process for fabricating off-the-shelf multilumen poly(ethylene glycol) (PEG)-based nerve guidance conduits (NGCs) was developed that included the use of stereolithography (SL). A rapid fabrication strategy for complex 3D scaffolds incorporated postprocessing with lyophilization and sterilization to preserve the scaffold, creating an implantable product with improved suturability. SL is easily adaptable to changes in scaffold design, is compatible with various materials and cells, and can be expanded for mass manufacture.

Combined micro and macro additive manufacturing of a swirling flow coaxial phacoemulsifier sleeve with internal micro-vanes.

Microstereolithography (microSL) technology can fabricate complex, three-dimensional (3D) microstructures, although microSL has difficulty producing macrostructures with micro-scale features. There are potentially many applications where 3D micro-features can benefit the overall function of the macrostructure. One such application involves a medical device called a coaxial phacoemulsifier where the tip of the phacoemulsifier is inserted into the eye through a relatively small incision and used to break the lens apart while removing the lens pieces and associated fluid from the eye through a small tube.

Hemodynamic comparison of differing anastomotic geometries using magnetic resonance velocimetry.

Background: Hemodynamic factors at the distal anastomosis play an important role in prosthetic graft performance. A new magnetic resonance imaging (MRI) technique was used to determine the effect of anastomotic geometry on hemodynamic flow patterns.

Methods: Four dimensional (4D) magnetic resonance velocimetry (4D-MRV) is a noninvasive method of analyzing pulsatile flow in three dimensions (3D).

Stereolithography of spatially controlled multi-material bioactive poly(ethylene glycol) scaffolds.

Challenges remain in tissue engineering to control the spatial, mechanical, temporal and biochemical architectures of scaffolds. Unique capabilities of stereolithography (SL) for fabricating multi-material spatially controlled bioactive scaffolds were explored in this work. To accomplish multi-material builds, a mini-vat setup was designed allowing for self-aligning X-Y registration during fabrication.

Automatic determination of pedicle screw size, length, and trajectory from patient data.

Pedicle screw insertion is an orthopaedic spinal fixation procedure involving the placement of screws through individual spine pedicles and secured in spinal vertebrae. Pedicle anatomy varies widely within and across the patient population, and many complications have been reported with the surgical technique. To reduce complications, an automated procedure was developed that utilizes patient-specific medical imaging data to predetermine optimum pedicle screw size, length, and trajectory.

Stereolithography of three-dimensional bioactive poly(ethylene glycol) constructs with encapsulated cells.

Stereolithography (SL) was used to fabricate complex 3-D poly(ethylene glycol) (PEG) hydrogels. Photopolymerization experiments were performed to characterize the solutions for use in SL, where the crosslinked depth (or hydrogel thickness) was measured at different laser energies and photoinitiator (PI) concentrations for two concentrations of PEG-dimethacrylate in solution (20% and 30% (w/v)). Hydrogel thickness was a strong function of PEG concentration, PI type and concentration, and energy dosage, and these results were utilized to successfully fabricate complex hydrogel structures using SL, including structures with internal channels of various orientations and multi-material structures.

Time-resolved three-dimensional phase-contrast MRI.

Purpose: To demonstrate the feasibility of a four-dimensional phase contrast (PC) technique that permits spatial and temporal coverage of an entire three-dimensional volume, to quantitatively validate its accuracy against an established time resolved two-dimensional PC technique to explore advantages of the approach with regard to the four-dimensional nature of the data.

Materials And Methods: Time-resolved, three-dimensional anatomical images were generated simultaneously with registered three-directional velocity vector fields. Improvements compared to prior methods include retrospectively gated and respiratory compensated image acquisition, interleaved flow encoding with freely selectable velocity encoding (venc) along each spatial direction, and flexible trade-off between temporal resolution and total acquisition time.