Materials Design ΚενοΤομια Processing/ Manufacturing
3D printing
From Concept, to Prototyping, to Production The Prototyping Process Can Be Long & Costly RAPID PROTOTYPING
Using the power of the Internet, it may eventually be possible to send a blueprint of any product to any place in the world to be replicated by a 3D printer with "elemental inks" capable of being combined into any material substance of any desired form. http://on3dprinting.com/tag/the-economist/
Manufacturing The Pyramids (~2500 B.C.) Captain Hook
Subtractive vs Additive Manufacturing http://www.dainiknation.com/p/games-news.html
Which to choose? Cost is critical e.g. CNC machining, Molding, etc. Q: Where CNC machining stands? CNC: Computerized Numerical Control http://dupress.com/articles/dr14-3d-opportunity/
Additive Manufacturing (ΑΜ) (or 3D Printing ) Why so much hype?
3D Printing Technologies * * * * Vat: καδος, δεξαμενη
Resin: Some Material Definitions Viscous Treatment Solid A natural or synthetic compound that begins in a highly viscous state and hardens with treatment. Thermoplastic: A polymer that becomes pliable or moldable above a specific temperature and solidifies upon cooling Photo-curable: Viscous Light (UV) Solid
Glass Transition Temperature, T g (most) Polymers can exist in 2 states: www.youtube.com/watch?v=03pw0ukh54k http://plastictechnologies.blogspot.gr/2011/03/glass-transition-temperature-tg.html http://www.fimmtech.com/index.php?id=6&subid=30
3D Printing: 4 ways CONCEPT: Material is FORMED or ADDED For an overview, read more: https://www.fictiv.com/resources/technology/overview-of-3d-printing-technologies
Fused Deposition Modeling (FDM)* CONCEPT: a plastic filament or metal wire is heated to its melting point and unwound from a coil. Heated Bed (~100 0 C) *trademarked & commercialized in 1990 by Stratasys Inc *best-selling rapid prototyping technology http://3devo.eu/guide-fdm-printable-plastics-3d-printing-filament/
FDM 3D printer in Action https://www.youtube.com/watch?v=fcgprtbpm9o
Materials for FDM ABS PLA https://www.youtube.com/watch?v=tc_z6jznfpy
FDM Biocompatible Materials PC-ISO = PolyCarbonate-ISO
Selective Laser Sintering (SLS) CONCEPT: Use of laser as the power source to sinter powdered material Used for plastics, ceramics, glass, metals, composites Need a binder Sintering: συντηξη Materials: any material that can be in powder form. Most common: nylon, glass-filled nylon, polystyrene, steel, titanium, alloy mixtures. http://www.mindtribe.com/2009/06/been-there-prototyped-that-what-process-and-when/
SLS in action https://www.youtube.com/watch?time_continue=57&v=x_rokgqylh0
StereoLithography (SLA) Concept: Focus an ultraviolet (UV) laser on to a vat of photopolymer resin. http://www.proform.ch/en/technolog ies/stereolithography.html Advantage: Speed Disadvantage: cost of the resin and of the machine
SLA and Materials
Σχετικο- Ασχετο: Inject Printing (2D) The nozzle http://www.memscentral.com /famous_mems_products.htm
Polyjet 3D Printing Concept: layers of liquid photopolymer are injected on a build tray and cured instantly with UV light Jetting Heads (one for the photopolymer and one for the support)
Polyjet in Action https://www.youtube.com/watch?v=omqwgbgnctg
Materials for Polyjet Printing Nearly 1,000 composite materials with specific, predictable properties - by blending two or three base resins. http://www.stratasys.com/materials/polyjet
Polyjet 3D Printing of Bio-compatible Materials
Which One to use? HOME APPLICA TIONS INDUSTRY APPLICATI ONS Table taken from: http://engl13123dprinting.weebly.com/literature-review.html
Some Numbers
Q: Can you 3D print Metals? YES! Selective Laser Sintering Watch at: www.youtube.com/watch?v=zapmgfda6ow Titanium Glasses The titanium implant has a large number of cavities. These weightreducing recesses in otherwise solid parts can only be achieved through Additive Manufacturing. http://www.eos.info/press/case_study/additive_manufactured_hip_implant
Q: Can you 3D Print Wood? YES! Selective Laser Sintering rough surface with a granular feel https://www.3printr.com/rinkak-offers-sls-3d-printing-service-using-wood-like-material-2628783/
3D printing: Applications in Medical Field
Story I: Rebuilding a face https://3dprint.com/59351/3d-print-face/ Q: could you make the implant not using 3D printing?
Story II: 3D-Airway Printed Splint The Problem: Tracheomalacia in babies occurs when cartilage in the trachea develops abnormally the tracheal walls collapse. The CT scan The 3D printed parts Watch the Story: www.youtube.com/watch?v=o82nc9ro6io
Story III: 3D-printed Vertebra (σπονδυλος) The Problem: A rare bone cancer can grow in the vertebra A normal spine model The traditional Titanium Tube 3D-printed artificial Vertebra Vertebra made out of titanium powder: the material most orthopedic implants are made from because it's biocompatible, light, and strong. The titanium replacement bone is filled with tiny pores that will allow real bone to naturally grow through it. http://www.businessinsider.com/3d-printing-can-create-replacement-bones-2014-8
Story 4: Scaffolds for Tissue Engineering Left to right: Sheep meniscus; 3-D model of meniscus obtained from laser scanning; 3-D printed anatomically correct meniscus scaffold http://newsroom.cumc.columbia.edu/blog/2014/12/10/3d-printed-meniscus/
3D Bio-Printing (or Tissue Engineering Meets 3D-Printing )
Evolution of Tissue Engineering 3D Bio-Printing http://engineering.org.cn/en/10.15302/j-eng-2015015
3D-Printing of Biomaterials
Printing a Vessel 3D print of a complex cardiovascular system http://guardianlv.com/2014/07/scientis ts-can-now-3d-print-working-bloodvessels/ http://beforeitsnews.com/alternative/2012/09/printing-evolves-an-inkjet-for-living-tissue-2468656.html
3D Print Skin Cells Onto Burn Wounds 3d scanning the wound Printing first layer of skin cells The Process: The laser scans the patient's burn and that information gets translated into a personalized plan for filling the wound up with cells. Then the inkjet printer lays down the cells individually, one layer at a time until the burned area is completely covered Printing second layer of skin cells http://www.3dprinterworld.com/article/wake-forest-3d-printsskin-cells-burn-wounds
Moving Forward: Functional Organs 3D-printing hydrogels impregnated with living chondrocyte cells those found in healthy cartilage. As well as printing the hydrogels and cells, a third ink containing nanosized conducting silver was added, and a coiled antenna printed in a specific site in the middle. These ears could pick up a range of frequencies much broader than non-bionic human ears can manage http://www.rsc.org/chemistryworld/2013/06/3d-printing
Direct Laser Writing for cells Acceptor Substrate Taken from: Laser Direct-Write Techniques for Printing of Complex Materials
3D Printing in the Micro/Nano Scale
MicroStereoLithography (msl) Concept: Photopattern a photosensitive polymer layer by layer to create a 3D structure You need: A liquid UV-curable Photopolymer A UV Laser A xyz Scanning System How: A UV light beam patterns the surface of a photopolymer layer by layer, causing polymerization or crosslinking After patterning, parts are cleaned by immersion in a chemical bath and then cured in a UV oven. Lateral Resolution: > 2 microns (depends on the depth)
Applications of msl Fun Tissue Engineering
Dip-Pen NanoLithography (DPN) Principle: The tip of a microscopic cantilever, coated with an ink, deposits ( writes ) a material on a substrate Tip Molecular Ink Specifications Resolution: 50 nm 10 mm Material That Can Be Deposited Molecular Inks: Alkane thiols, Silanes Liquid Inks: Proteins, Peptides, DNA, Hydrogels Liquid Inks DPN is a scanning probe technique that originated from Atomic Force Microscopy
Variations of DPN A. Thermal DPN B. Electro PN Solid Ink Heated cantilever C. Nano Fountain Pen
DPN Nanoarrays to Detect Viruses ADNANTAGES Nanoarrays can hold 10 4 10 5 more features than conventional microarrays Decreased sample volumes Detection of a smaller number of target molecules for a given analyte concentration (lower limit of detection) DISADNANTAGES? Reade More at: Applications of dip-pen nanolithography, Nature nanotechnology VOL 2 MARCH 2007