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Article ; Online: Support Removal on Thin-Walled Parts Produced by Laser Powder Bed Fusion.

Cao, Qiqiang / Bai, Yuchao / Zheng, Zhongpeng / Zhang, Jiong / Fuh, Jerry Ying Hsi / Wang, Hao

3D printing and additive manufacturing

2023 Volume 10, Issue 4, Page(s) 762–775

Abstract: Support removal is one of the thorny issues faced by laser powder bed fusion (LPBF). In particular, the efficient and safe removal of support structures from the thin-walled parts and obtaining high-quality surfaces still remains a challenge owing to ... ...

Abstract	Support removal is one of the thorny issues faced by laser powder bed fusion (LPBF). In particular, the efficient and safe removal of support structures from the thin-walled parts and obtaining high-quality surfaces still remains a challenge owing to their sensitivity to machining. An in-depth understanding of the material response behavior of LPBF thin-walled parts when removing support structures is necessary for overcoming this challenge. The work is divided into two parts: revealing the support removal mechanism and proposing a solution to improve the support machinability. First, the machinability of support structures on thin-walled parts with different thicknesses at different cutting depths was thoroughly investigated. Experimental investigation on cutting force, surface morphology, and deflection were carried out. The results show that cutting forces increase gradually at each cut owing to the tilt and collapse of support structures. The surface morphology is improved as the sample thickness increases but deteriorated as the cutting depth increases. Second, a novel solution of adding resin is proposed to improve the support machinability and good results have been achieved. The
Language	English
Publishing date	2023-08-09
Publishing country	United States
Document type	Journal Article
ISSN	2329-7670
ISSN (online)	2329-7670
DOI	10.1089/3dp.2021.0268
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Article ; Online: Metal-based additive manufacturing condition monitoring methods: From measurement to control.

Lin, Xin / Zhu, Kunpeng / Fuh, Jerry Ying Hsi / Duan, Xianyin

ISA transactions

2021 Volume 120, Page(s) 147–166

Abstract: Compared with other additive manufacturing processes, the metal-based additive manufacturing (MAM) can build higher precision and higher density parts, and have unique advantages in the applications to automotive, medical, and aerospace industries. ... ...

Abstract	Compared with other additive manufacturing processes, the metal-based additive manufacturing (MAM) can build higher precision and higher density parts, and have unique advantages in the applications to automotive, medical, and aerospace industries. However, the quality defects of builds, such as dimensional accuracy, layer morphology, mechanical and metallurgical defects, have been hindering the wide applications of MAM technologies. These decrease the repeatability and consistency of build quality. In order to overcome these shortcomings and to produce high-quality parts, it is very important to carry out online monitoring and process control in the building process. A process monitoring system is demanded which can automatically optimize the process parameters to eliminate incipient defects, improve the process stability and the final build quality. In this paper, the current representative studies are selected from the literature, and the research progress of MAM process monitoring and control are surveyed. Taking the key components of the MAM monitoring system as the mainstream, this study investigates the MAM monitoring system, measurement and signal acquisition, signal and image processing, as well as machine learning methods for the process monitoring and quality classification. The advantages and disadvantages of their algorithmic implementations and applications are discussed and summarized. Finally, the prospects of MAM process monitoring researches are advised.
Language	English
Publishing date	2021-03-05
Publishing country	United States
Document type	Journal Article
ZDB-ID	2012746-7
ISSN	1879-2022 ; 0019-0578
ISSN (online)	1879-2022
ISSN	0019-0578
DOI	10.1016/j.isatra.2021.03.001
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Article ; Online: Bioprinting and biofabrication for tissue engineering in Asia.

Vijayavenkataraman, Sanjairaj / Feng, Lu Wen / Fuh, Jerry Ying Hsi

International journal of bioprinting

2019 Volume 5, Issue 2.1, Page(s) 231

Language	English
Publishing date	2019-09-18
Publishing country	Singapore
Document type	Editorial
ZDB-ID	2834694-4
ISSN	2424-8002 ; 2424-7723
ISSN (online)	2424-8002
ISSN	2424-7723
DOI	10.18063/ijb.v5i2.1.231
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Article ; Online: Intelligent modeling and monitoring of micro-droplet profiles in 3D printing.

Lin, Xin / Zhu, Kunpeng / Zhou, Jinxin / Fuh, Jerry Ying Hsi

ISA transactions

2020 Volume 105, Page(s) 367–376

Abstract: The inkjet 3D printing has been one of the most studied and applied additive manufacturing (AM) processes in electronic industry. In this AM process, the forming quality is greatly influenced by the micro-droplet deposition and substrate temperature. ... ...

Abstract	The inkjet 3D printing has been one of the most studied and applied additive manufacturing (AM) processes in electronic industry. In this AM process, the forming quality is greatly influenced by the micro-droplet deposition and substrate temperature. While most studies focus on the formation mechanism of droplets, there are few studies on the quantitative evaluation of the droplet surface profile and its qualitative correlation with temperature changes. In this study, the characteristics of droplet profile in three-dimensional inkjet printing were studied from two aspects, the modeling of droplet shape and the estimation of droplet temperature. For this purpose, different types of radial basis function networks (RBFN) are applied. The validity of the regularized RBFN model is developed and verified by experiments. The results show that the droplet shape can be accurately modeled and the drying temperature can be accurately estimated given the model.
Language	English
Publishing date	2020-05-27
Publishing country	United States
Document type	Journal Article
ZDB-ID	2012746-7
ISSN	1879-2022 ; 0019-0578
ISSN (online)	1879-2022
ISSN	0019-0578
DOI	10.1016/j.isatra.2020.05.030
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Article ; Online: A biomechanical evaluation on Cubic, Octet, and TPMS gyroid Ti6Al4V lattice structures fabricated by selective laser melting and the effects of their debris on human osteoblast-like cells.

Wang, Niyou / Meenashisundaram, Ganesh Kumar / Kandilya, Deepika / Fuh, Jerry Ying Hsi / Dheen, S Thameem / Kumar, A Senthil

Biomaterials advances

2022 Volume 137, Page(s) 212829

Abstract: Lattice structures are widely used in orthopedic implants due to their unique features, such as high strength-to-weight ratios and adjustable biomechanical properties. Based on the type of unit cell geometry, lattice structures may be classified into two ...

Abstract	Lattice structures are widely used in orthopedic implants due to their unique features, such as high strength-to-weight ratios and adjustable biomechanical properties. Based on the type of unit cell geometry, lattice structures may be classified into two types: strut-based structures and sheet-based structures. In this study, strut-based structures (Cubic & Octet) and sheet-based structure (triply periodic minimal surface (TPMS) gyroid) were investigated. The biomechanical properties of the three different Ti6Al4V lattice structures fabricated by selective laser melting (SLM) were investigated using room temperature compression testing. Scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) were used to check the 3D printing quality with regards to defects and quantitative compositional information of 3D printed parts. Experimental results indicated that TPMS gyroid has superior biomechanical properties when compared to Cubic and Octet. Also, TPMS gyroid was found to be less affected by the variations in relative density. The biocompatibility of Ti6Al4V lattice structures was validated through the cytotoxicity test with human osteoblast-like SAOS2 cells. The debris generated during the degradation process in the form of particles and ions is among the primary causes of implant failure over time. In this study, Ti6Al4V particles with spherical and irregular shapes having average particle sizes of 36.5 μm and 28.8 μm, respectively, were used to mimic the actual Ti6Al4V particles to understand their harmful effects better. Also, the effects and amount of Ti6Al4V ions released after immersion within the cell culture media were investigated using the indirect cytotoxicity test and ion release test.
MeSH term(s)	Alloys ; Humans ; Lasers ; Materials Testing ; Osteoblasts ; Porosity ; Titanium
Chemical Substances	Alloys ; titanium alloy (TiAl6V4) (12743-70-3) ; Titanium (D1JT611TNE)
Language	English
Publishing date	2022-04-28
Publishing country	Netherlands
Document type	Journal Article
ISSN	2772-9508
ISSN (online)	2772-9508
DOI	10.1016/j.bioadv.2022.212829
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Article ; Online: A comparative investigation on the mechanical properties and cytotoxicity of Cubic, Octet, and TPMS gyroid structures fabricated by selective laser melting of stainless steel 316L.

Wang, Niyou / Meenashisundaram, Ganesh Kumar / Chang, Shuai / Fuh, Jerry Ying Hsi / Dheen, S Thameem / Senthil Kumar, A

Journal of the mechanical behavior of biomedical materials

2022 Volume 129, Page(s) 105151

Abstract: Metallic lattice structures can be fabricated by selective laser melting (SLM) with purposefully designed pores and controlled pore sizes that can bio mimic the natural bone, providing adequate mechanical and biological support for the patients. Strut- ... ...

Abstract	Metallic lattice structures can be fabricated by selective laser melting (SLM) with purposefully designed pores and controlled pore sizes that can bio mimic the natural bone, providing adequate mechanical and biological support for the patients. Strut-based structures, like Cubic, Octet; and sheet-based structures, like triply periodic minimal surface (TPMS) gyroid, have been studied extensively in the past. However, it lacks enough comparative study on the mechanical properties and cytotoxicity among these structures. Therefore, Cubic, Octet, and TPMS gyroid of Stainless steel 316 L (SS316L) are designed, manufactured, and characterized at 40/50/60% relative densities in this study. Moreover, the flowability, density characteristics, and cytotoxicity of SS316L powder are validated to ascertain its suitability for 3D printing and implant application. Based on refining the Gibson-Ashby model, it is possible to predict or design the mechanical properties via adjusting the relative densities. The results indicate these structures demonstrated appropriate Young's modulus and outstanding biocompatibility.
MeSH term(s)	Bone and Bones ; Elastic Modulus ; Humans ; Lasers ; Porosity ; Stainless Steel
Chemical Substances	Stainless Steel (12597-68-1)
Language	English
Publishing date	2022-03-02
Publishing country	Netherlands
Document type	Journal Article ; Research Support, Non-U.S. Gov't
ZDB-ID	2378381-3
ISSN	1878-0180 ; 1751-6161
ISSN (online)	1878-0180
ISSN	1751-6161
DOI	10.1016/j.jmbbm.2022.105151
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Article ; Online: Effect of Porosity on Mechanical Properties of 3D Printed Polymers: Experiments and Micromechanical Modeling Based on X-ray Computed Tomography Analysis.

Wang, Xue / Zhao, Liping / Fuh, Jerry Ying Hsi / Lee, Heow Pueh

Polymers

2019 Volume 11, Issue 7

Abstract: Additive manufacturing (commonly known as 3D printing) is defined as a family of technologies that deposit and consolidate materials to create a 3D object as opposed to subtractive manufacturing methodologies. Fused deposition modeling (FDM), one of the ... ...

Abstract	Additive manufacturing (commonly known as 3D printing) is defined as a family of technologies that deposit and consolidate materials to create a 3D object as opposed to subtractive manufacturing methodologies. Fused deposition modeling (FDM), one of the most popular additive manufacturing techniques, has demonstrated extensive applications in various industries such as medical prosthetics, automotive, and aeronautics. As a thermal process, FDM may introduce internal voids and pores into the fabricated thermoplastics, giving rise to potential reduction on the mechanical properties. This paper aims to investigate the effects of the microscopic pores on the mechanical properties of material fabricated by the FDM process via experiments and micromechanical modeling. More specifically, the three-dimensional microscopic details of the internal pores, such as size, shape, density, and spatial location were quantitatively characterized by X-ray computed tomography (XCT) and, subsequently, experiments were conducted to characterize the mechanical properties of the material. Based on the microscopic details of the pores characterized by XCT, a micromechanical model was proposed to predict the mechanical properties of the material as a function of the porosity (ratio of total volume of the pores over total volume of the material). The prediction results of the mechanical properties were found to be in agreement with the experimental data as well as the existing works. The proposed micromechanical model allows the future designers to predict the elastic properties of the 3D printed material based on the porosity from XCT results. This provides a possibility of saving the experimental cost on destructive testing.
Language	English
Publishing date	2019-07-05
Publishing country	Switzerland
Document type	Journal Article
ZDB-ID	2527146-5
ISSN	2073-4360 ; 2073-4360
ISSN (online)	2073-4360
ISSN	2073-4360
DOI	10.3390/polym11071154
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Article ; Online: Functions and applications of metallic and metallic oxide nanoparticles in orthopedic implants and scaffolds.

Wang, Niyou / Fuh, Jerry Ying Hsi / Dheen, S Thameem / Senthil Kumar, A

Journal of biomedical materials research. Part B, Applied biomaterials

2020 Volume 109, Issue 2, Page(s) 160–179

Abstract: Bone defects and diseases are devastating, and can lead to severe functional deficits or even permanent disability. Nevertheless, orthopedic implants and scaffolds can facilitate the growth of incipient bone and help us to treat bone defects and diseases. ...

Abstract	Bone defects and diseases are devastating, and can lead to severe functional deficits or even permanent disability. Nevertheless, orthopedic implants and scaffolds can facilitate the growth of incipient bone and help us to treat bone defects and diseases. Currently, a wide range of biomaterials with distinct biocompatibility, biodegradability, porosity, and mechanical strength is used in bone-related research. However, most orthopedic implants and scaffolds have certain limitations and diverse complications, such as limited corrosion resistance, low cell proliferation, and bacterial adhesion. With recent advancements in materials science and nanotechnology, metallic and metallic oxide nanoparticles have become the subject of significant interest as they offer an ample variety of options to resolve the existing problems in the orthopedic industry. More importantly, these nanoparticles possess unique physicochemical and mechanical properties not found in conventional materials, and can be incorporated into orthopedic implants and scaffolds to enhance their antimicrobial ability, bioactive molecular delivery, mechanical strength, osteointegration, and cell labeling and imaging. However, many metallic and metallic oxide nanoparticles can also be toxic to nearby cells and tissues. This review article will discuss the applications and functions of metallic and metallic oxide nanoparticles in orthopedic implants and bone tissue engineering.
MeSH term(s)	Alloys/adverse effects ; Alloys/therapeutic use ; Biocompatible Materials/adverse effects ; Biocompatible Materials/therapeutic use ; Corrosion ; Humans ; Metal Nanoparticles/adverse effects ; Metal Nanoparticles/therapeutic use ; Oxides/adverse effects ; Oxides/therapeutic use ; Prostheses and Implants
Chemical Substances	Alloys ; Biocompatible Materials ; Oxides
Language	English
Publishing date	2020-08-09
Publishing country	United States
Document type	Journal Article ; Research Support, Non-U.S. Gov't ; Review
ZDB-ID	2099992-6
ISSN	1552-4981 ; 1552-4973 ; 0021-9304
ISSN (online)	1552-4981
ISSN	1552-4973 ; 0021-9304
DOI	10.1002/jbm.b.34688
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Article ; Online: Metallic 4D Printing of Laser Stimulation.

Wu, Wenzheng / Zhou, Yiming / Liu, Qingping / Ren, Luquan / Chen, Fan / Fuh, Jerry Ying Hsi / Zheng, Aodu / Li, Xuechao / Zhao, Ji / Li, Guiwei

Advanced science (Weinheim, Baden-Wurttemberg, Germany)

2023 Volume 10, Issue 12, Page(s) e2206486

Abstract: 4D printing of metallic shape-morphing systems can be applied in many fields, including aerospace, smart manufacturing, naval equipment, and biomedical engineering. The existing forming materials for metallic 4D printing are still very limited except ... ...

Abstract	4D printing of metallic shape-morphing systems can be applied in many fields, including aerospace, smart manufacturing, naval equipment, and biomedical engineering. The existing forming materials for metallic 4D printing are still very limited except shape memory alloys. Herein, a 4D printing method to endow non-shape-memory metallic materials with active properties is presented, which could overcome the shape-forming limitation of traditional material processing technologies. The thermal stress spatial control of 316L stainless steel forming parts is achieved by programming the processing parameters during a laser powder bed fusion (LPBF) process. The printed parts can realize the shape changing of selected areas during or after forming process owing to stress release generated. It is demonstrated that complex metallic shape-morphing structures can be manufactured by this method. The principles of printing parameters programmed and thermal stress pre-set are also applicable to other thermoforming materials and additive manufacturing processes, which can expand not only the materials used for 4D printing but also the applications of 4D printing technologies.
Language	English
Publishing date	2023-01-22
Publishing country	Germany
Document type	Journal Article
ZDB-ID	2808093-2
ISSN	2198-3844 ; 2198-3844
ISSN (online)	2198-3844
ISSN	2198-3844
DOI	10.1002/advs.202206486
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Article ; Online: Degradation behaviors of geometric cues and mechanical properties in a 3D scaffold for tendon repair.

Wu, Yang / Wong, Yoke San / Fuh, Jerry Ying Hsi

Journal of biomedical materials research. Part A

2017 Volume 105, Issue 4, Page(s) 1138–1149

Abstract: A three-dimensional (3D) scaffold fabricated via electrohydrodynamic jet printing (E-jetting) and thermally uniaxial stretching, has been developed for tendon tissue regeneration in our previous study. In this study, more in-depth biological test showed ... ...

Abstract	A three-dimensional (3D) scaffold fabricated via electrohydrodynamic jet printing (E-jetting) and thermally uniaxial stretching, has been developed for tendon tissue regeneration in our previous study. In this study, more in-depth biological test showed that the aligned cell morphology guided by the anisotropic geometries of the 3D tendon scaffolds, leading to up-regulated tendious gene expression including collagen type I, decorin, tenascin-C, and biglycan, as compared to the electrospun scaffolds. Given the importance of geometric cues to the biological function of the scaffolds, the degradation behaviors of the 3D scaffolds were investigated. Results from accelerated hydrolysis showed that the E-jetted portion followed bulk-controlled erosion, while the unaixially stretched portion followed surface-controlled erosion. The 3D tendon scaffold exhibited consistency between the weight loss and the decline of mechanical properties, which indicated by a 65% decrease in mass with a corresponding 56% loss in ultimate tensile strength after degradation. This study not only reveals that the anisotropic geometries of 3D tendon scaffold could affect cell morphology and lead to desired gene expression toward tendon tissue but also gives an insight into how the degradation impacts geometric cues and mechanical properties of the as-fabricated scaffold. © 2017 Wiley Periodicals, Inc. J Biomed Mater Res Part A: 105A: 1138-1149, 2017.
MeSH term(s)	Cell Line ; Tendon Injuries/metabolism ; Tendon Injuries/pathology ; Tendon Injuries/therapy ; Tenocytes/metabolism ; Tenocytes/pathology ; Tissue Scaffolds/chemistry
Language	English
Publishing date	2017-04
Publishing country	United States
Document type	Journal Article
ZDB-ID	2099989-6
ISSN	1552-4965 ; 1549-3296 ; 0021-9304
ISSN (online)	1552-4965
ISSN	1549-3296 ; 0021-9304
DOI	10.1002/jbm.a.35966
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