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Article ; Online: One-Shot 3D Printed Soft Device Actuated Using Metal-Filled Channels and Sensed with Embedded Strain Gauge.

Pavone, Antonio / Stano, Gianni / Percoco, Gianluca

3D printing and additive manufacturing

2023 Volume 10, Issue 6, Page(s) 1251–1259

Abstract: In this article, the multimaterial extrusion (M-MEX) technology is used to fabricate, in a single step, a three-dimensional printed soft electromagnetic (EM) actuator, based on internal channels, filled with soft liquid metal (Galinstan) and equipped ... ...

Abstract	In this article, the multimaterial extrusion (M-MEX) technology is used to fabricate, in a single step, a three-dimensional printed soft electromagnetic (EM) actuator, based on internal channels, filled with soft liquid metal (Galinstan) and equipped with an embedded strain gauge, for the first time. At the state of the art, M-MEX techniques result underexploited for the manufacture of soft EM actuators: only traditional manufacturing approaches are used, resulting in many assembly steps. The main features of this work are as follows: (1) one shot fabrication, (2) smart structure equipped with sensor unit, and (3) scalability. The actuator was tested in conjunction with a commercial magnet, showing a bending angle of 22.4° (when activated at 4A), a relative error of 0.7%, and a very high sensor sensitivity of 49.7 Two more examples, showing all the potentialities of the proposed approach, are presented: a jumping frog-inspired soft robot and a dual independent two-finger actuator. This article aims to push the role of extrusion-based additive manufacturing for the fabrication of EM soft robots: several advantages such as portability, no cooling systems, fast responses, and noise reduction can be achieved by exploiting the proposed actuation system compared to the traditional and widespread actuation mechanisms (shape memory polymers, shape memory alloys, pneumatic actuation, and cable-driven actuation).
Language	English
Publishing date	2023-12-11
Publishing country	United States
Document type	Journal Article
ISSN	2329-7670
ISSN (online)	2329-7670
DOI	10.1089/3dp.2022.0263
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Article ; Online: Additive Manufacturing for Bioinspired Structures: Experimental Study to Improve the Multimaterial Adhesion Between Soft and Stiff Materials.

Stano, Gianni / Ovy, S M Al Islam / Percoco, Gianluca / Zhang, Runyu / Lu, Hongbing / Tadesse, Yonas

3D printing and additive manufacturing

2023 Volume 10, Issue 5, Page(s) 1080–1089

Abstract: The fabrication of bioinspired structures has recently gained an increasing popularity: mimicking the way in which nature develops structures is a vital prerequisite in soft robotics to achieve multiple benefits. Stiff structures connected by soft joints ...

Abstract	The fabrication of bioinspired structures has recently gained an increasing popularity: mimicking the way in which nature develops structures is a vital prerequisite in soft robotics to achieve multiple benefits. Stiff structures connected by soft joints (recalling, for instance, human bones connected by cartilage) are highly appealing: several prototypes have been manufactured and tested, demonstrating their full potential. In the present research, the material extrusion (MEX) additive manufacturing technology has been used to manufacture stiff-soft bioinspired structures activated by shape memory alloy (SMA) actuators. First, three commercially available stiff composite plastic materials were investigated and linked to different 3D printing infills. Surprisingly, we found that the "gyroid" infill was correlated to the mechanical properties, demonstrating that it produces better results in terms of Young's modulus and ultimate tensile strength (UTS) than the widely studied "lines" infill. The primary focus of the research is an experimental study aimed at improving the adhesion at the interface between stiff and soft materials using an inexpensive method (i.e., MEX). Three different variables that have significant effects on the interface bonding were studied: (1) the interface geometry between stiff and soft parts, (2) the mesh overlapping process parameter, and (3) the annealing post-treatment. By optimizing the three variables, a Young's modulus of 48.8 MPa and a UTS of 3.8 MPa were achieved, when nylon+glass fiber (a stiff material) and thermoplastic polyurethane (a soft material) were 3D printed together. In particular, the 3.8 MPa UTS is 48% higher than the highest adhesion between the soft and stiff material (thermoplastic polyurethane [TPU] and acrylonitrile butadiene styrene) reported in literature. Finally, taking advantage of the improved stiff-soft adhesion, a bioinspired robotic finger has been fabricated and tested using an SMA actuator, showing an enormous potential for the proposed additive manufacturing approach in realizing bioinspired systems.
Language	English
Publishing date	2023-10-10
Publishing country	United States
Document type	Journal Article
ISSN	2329-7670
ISSN (online)	2329-7670
DOI	10.1089/3dp.2022.0186
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Article: Fused Filament Fabrication (FFF) for Manufacturing of Microfluidic Micromixers: An Experimental Study on the Effect of Process Variables in Printed Microfluidic Micromixers.

Zeraatkar, Mojtaba / de Tullio, Marco D / Percoco, Gianluca

Micromachines

2021 Volume 12, Issue 8

Abstract: The need for accessible and inexpensive microfluidic devices requires new manufacturing methods and materials as a replacement for traditional soft lithography and polydimethylsiloxane (PDMS). Recently, with the advent of modern additive manufacturing ( ... ...

Abstract	The need for accessible and inexpensive microfluidic devices requires new manufacturing methods and materials as a replacement for traditional soft lithography and polydimethylsiloxane (PDMS). Recently, with the advent of modern additive manufacturing (AM) techniques, 3D printing has attracted attention for its use in the fabrication of microfluidic devices and due to its automated, assembly-free 3D fabrication, rapidly decreasing cost, and fast-improving resolution and throughput. Here, fused filament fabrication (FFF) 3D printing was used to create microfluidic micromixers and enhance the mixing process, which has been identified as a challenge in microfluidic devices. A design of experiment (DoE) was performed on the effects of studied parameters in devices that were printed by FFF. The results of the colorimetric approach showed the effects of different parameters on the mixing process and on the enhancement of the mixing performance in printed devices. The presence of the geometrical features on the microchannels can act as ridges due to the nature of the FFF process. In comparison to passive and active methods, no complexity was added in the fabrication process, and the ridges are an inherent property of the FFF process.
Language	English
Publishing date	2021-07-22
Publishing country	Switzerland
Document type	Journal Article
ZDB-ID	2620864-7
ISSN	2072-666X
ISSN	2072-666X
DOI	10.3390/mi12080858
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Article ; Online: Analytical and Numerical Models of Thermoplastics: A Review Aimed to Pellet Extrusion-Based Additive Manufacturing.

Pricci, Alessio / de Tullio, Marco D / Percoco, Gianluca

Polymers

2021 Volume 13, Issue 18

Abstract: Recent developments in additive manufacturing have moved towards a new trend in material extrusion processes (ISO/ASTM 52910:2018), dealing with the direct extrusion of thermoplastic and composite material from pellets. This growing interest is driven by ...

Abstract	Recent developments in additive manufacturing have moved towards a new trend in material extrusion processes (ISO/ASTM 52910:2018), dealing with the direct extrusion of thermoplastic and composite material from pellets. This growing interest is driven by the reduction of costs, environmental impact, energy consumption, and the possibility to increase the range of printable materials. Pellet additive manufacturing (PAM) can cover the same applications as fused filament fabrication (FFF), and in addition, can lead to scale towards larger workspaces that cannot be covered by FFF, due to the limited diameters of standard filaments. In the first case, the process is known as micro- or mini-extrusion (MiE) in the literature, in the second case the expression big area additive manufacturing (BAAM) is very common. Several models are available in literature regarding filament extrusion, while there is a lack of modeling of the extrusion dynamics in PAM. Physical and chemical phenomena involved in PAM have high overlap with those characterizing injection molding (IM). Therefore, a systematic study of IM literature can lead to a selection of the most promising models for PAM, both for lower (MiE) and larger (BAAM) extruder dimensions. The models concerning the IM process have been reviewed with this aim: the extraction of information useful for the development of codes able to predict thermo-fluid dynamics performances of PAM extruders.
Language	English
Publishing date	2021-09-18
Publishing country	Switzerland
Document type	Journal Article ; Review
ZDB-ID	2527146-5
ISSN	2073-4360 ; 2073-4360
ISSN (online)	2073-4360
ISSN	2073-4360
DOI	10.3390/polym13183160
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Article: Additive Manufacturing for Soft Robotics: Design and Fabrication of Airtight, Monolithic Bending PneuNets with Embedded Air Connectors.

Stano, Gianni / Arleo, Luca / Percoco, Gianluca

Micromachines

2020 Volume 11, Issue 5

Abstract: Air tightness is a challenging task for 3D-printed components, especially for fused filament fabrication (FFF), due to inherent issues, related to the layer-by-layer fabrication method. On the other hand, the capability of 3D print airtight cavities with ...

Abstract	Air tightness is a challenging task for 3D-printed components, especially for fused filament fabrication (FFF), due to inherent issues, related to the layer-by-layer fabrication method. On the other hand, the capability of 3D print airtight cavities with complex shapes is very attractive for several emerging research fields, such as soft robotics. The present paper proposes a repeatable methodology to 3D print airtight soft actuators with embedded air connectors. The FFF process has been optimized to manufacture monolithic bending PneuNets (MBPs), an emerging class of soft robots. FFF has several advantages in soft robot fabrication: (i) it is a fully automated process which does not require manual tasks as for molding, (ii) it is one of the most ubiquitous and inexpensive (FFF 3D printers costs < $200) 3D-printing technologies, and (iii) more materials can be used in the same printing cycle which allows embedding of several elements in the soft robot body. Using commercial soft filaments and a dual-extruder 3D printer, at first, a novel air connector which can be easily embedded in each soft robot, made via FFF technology with a single printing cycle, has been fabricated and tested. This new embedded air connector (EAC) prevents air leaks at the interface between pneumatic pipe and soft robot and replaces the commercial air connections, often origin of leakages in soft robots. A subsequent experimental study using four different shapes of MBPs, each equipped with EAC, showed the way in which different design configurations can affect bending performance. By focusing on the best performing shape, among the tested ones, the authors studied the relationship between bending performance and air tightness, proving how the Design for Additive Manufacturing approach is essential for advanced applications involving FFF. In particular, the relationship between chamber wall thickness and printing parameters has been analyzed, the thickness of the walls has been studied from 1.6 to 1 mm while maintaining air tightness and improving the bending angle by 76.7% under a pressure of 4 bar. It emerged that the main printing parameter affecting chamber wall air tightness is the line width that, in conjunction with the wall thickness, can ensure air tightness of the soft actuator body.
Language	English
Publishing date	2020-05-09
Publishing country	Switzerland
Document type	Journal Article
ZDB-ID	2620864-7
ISSN	2072-666X
ISSN	2072-666X
DOI	10.3390/mi11050485
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Article: On the Impact of the Fabrication Method on the Performance of 3D Printed Mixers.

Zeraatkar, Mojtaba / Filippini, Daniel / Percoco, Gianluca

Micromachines

2019 Volume 10, Issue 5

Abstract: A wide variety of 3D printing technologies have been used for the fabrication of lab-on-a-chip (LOC) devices in recent years. Despite the large number of studies having examined the use of 3D printing technologies in microfluidic devices, the effect of ... ...

Abstract	A wide variety of 3D printing technologies have been used for the fabrication of lab-on-a-chip (LOC) devices in recent years. Despite the large number of studies having examined the use of 3D printing technologies in microfluidic devices, the effect of the fabrication method on their performance has received little attention. In this paper, a comparison is shown between unibody-LOC micro-mixers, a particular type of monolithic design for 3D printed LOCs, fabricated in polyjet, stereolithography (SLA) and fused deposition modelling (FDM or FFF) platforms, paying particular attention to the inherent limitations of each fabrication platform and how these affect the performance of the manufactured devices.
Language	English
Publishing date	2019-04-30
Publishing country	Switzerland
Document type	Journal Article
ZDB-ID	2620864-7
ISSN	2072-666X
ISSN	2072-666X
DOI	10.3390/mi10050298
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Article ; Online: Thermal Characterization of New 3D-Printed Bendable, Coplanar Capacitive Sensors.

Ragolia, Mattia Alessandro / Lanzolla, Anna M L / Percoco, Gianluca / Stano, Gianni / Di Nisio, Attilio

Sensors (Basel, Switzerland)

2021 Volume 21, Issue 19

Abstract: In this paper a new low-cost stretchable coplanar capacitive sensor for liquid level sensing is presented. It has been 3D-printed by employing commercial thermoplastic polyurethane (TPU) and conductive materials and using a fused filament fabrication ( ... ...

Abstract	In this paper a new low-cost stretchable coplanar capacitive sensor for liquid level sensing is presented. It has been 3D-printed by employing commercial thermoplastic polyurethane (TPU) and conductive materials and using a fused filament fabrication (FFF) process for monolithic fabrication. The sensor presents high linearity and good repeatability when measuring sunflower oil level. Experiments were performed to analyse the behaviour of the developed sensor when applying bending stimuli, in order to verify its flexibility, and a thermal characterization was performed in the temperature range from 10 °C to 40 °C to evaluate its effect on sunflower oil level measurement. The experimental results showed negligible sensitivity of the sensor to bending stimuli, whereas the thermal characterization produced a model describing the relationship between capacitance, temperature, and oil level, allowing temperature compensation in oil level measurement. The different temperature cycles allowed to quantify the main sources of uncertainty, and their effect on level measurement was evaluated.
MeSH term(s)	Electric Capacitance ; Electric Conductivity ; Polyurethanes ; Printing, Three-Dimensional ; Temperature
Chemical Substances	Polyurethanes
Language	English
Publishing date	2021-09-22
Publishing country	Switzerland
Document type	Journal Article
ZDB-ID	2052857-7
ISSN	1424-8220 ; 1424-8220
ISSN (online)	1424-8220
ISSN	1424-8220
DOI	10.3390/s21196324
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Article: Extrusion-Based 3D Printing of Microfluidic Devices for Chemical and Biomedical Applications: A Topical Review.

Pranzo, Daniela / Larizza, Piero / Filippini, Daniel / Percoco, Gianluca

Micromachines

2018 Volume 9, Issue 8

Abstract: One of the most widespread additive manufacturing (AM) technologies is fused deposition modelling (FDM), also known as fused filament fabrication (FFF) or extrusion-based AM. The main reasons for its success are low costs, very simple machine structure, ... ...

Abstract	One of the most widespread additive manufacturing (AM) technologies is fused deposition modelling (FDM), also known as fused filament fabrication (FFF) or extrusion-based AM. The main reasons for its success are low costs, very simple machine structure, and a wide variety of available materials. However, one of the main limitations of the process is its accuracy and finishing. In spite of this, FDM is finding more and more applications, including in the world of micro-components. In this world, one of the most interesting topics is represented by microfluidic reactors for chemical and biomedical applications. The present review focusses on this research topic from a process point of view, describing at first the platforms and materials and then deepening the most relevant applications.
Language	English
Publishing date	2018-07-27
Publishing country	Switzerland
Document type	Journal Article ; Review
ZDB-ID	2620864-7
ISSN	2072-666X
ISSN	2072-666X
DOI	10.3390/mi9080374
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Article: Investigating the Potential of Commercial-Grade Carbon Black-Filled TPU for the 3D Printing of Compressive Sensors.

Manganiello, Claudio / Naso, David / Cupertino, Francesco / Fiume, Orazio / Percoco, Gianluca

Micromachines

2019 Volume 10, Issue 1

Abstract: The present research aims to exploit commercially available materials and machines to fabricate multilayer, topologically designed transducers, which can be embedded into mechanical devices, such as soft or rigid grippers. Preliminary tests on the ... ...

Abstract	The present research aims to exploit commercially available materials and machines to fabricate multilayer, topologically designed transducers, which can be embedded into mechanical devices, such as soft or rigid grippers. Preliminary tests on the possibility of fabricating 3D-printed transducers using a commercial conductive elastomeric filament, carbon black-filled thermoplastic polyurethane, are presented. The commercial carbon-filled thermoplastic polyurethane (TPU), analyzed in the present paper, has proven to be a candidate material for the production of 3D printed displacement sensors. Some limitations in fabricating the transducers from a 2.85 mm filament were found, and comparisons with 1.75 mm filaments should be conducted. Moreover, further research on the low repeatability at low displacements and the higher performance of the hollow structure, in terms of repeatability, must be carried out. To propose an approach that can very easily be reproduced, only commercial filaments are used.
Language	English
Publishing date	2019-01-10
Publishing country	Switzerland
Document type	Journal Article
ZDB-ID	2620864-7
ISSN	2072-666X
ISSN	2072-666X
DOI	10.3390/mi10010046
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Article: Mechanobiological Approach to Design and Optimize Bone Tissue Scaffolds 3D Printed with Fused Deposition Modeling: A Feasibility Study.

Percoco, Gianluca / Uva, Antonio Emmanuele / Fiorentino, Michele / Gattullo, Michele / Manghisi, Vito Modesto / Boccaccio, Antonio

Materials (Basel, Switzerland)

2020 Volume 13, Issue 3

Abstract: In spite of the rather large use of the fused deposition modeling (FDM) technique for the fabrication of scaffolds, no studies are reported in the literature that optimize the geometry of such scaffold types based on mechanobiological criteria. We ... ...

Abstract	In spite of the rather large use of the fused deposition modeling (FDM) technique for the fabrication of scaffolds, no studies are reported in the literature that optimize the geometry of such scaffold types based on mechanobiological criteria. We implemented a mechanobiology-based optimization algorithm to determine the optimal distance between the strands in cylindrical scaffolds subjected to compression. The optimized scaffolds were then 3D printed with the FDM technique and successively measured. We found that the difference between the optimized distances and the average measured ones never exceeded 8.27% of the optimized distance. However, we found that large fabrication errors are made on the filament diameter when the filament diameter to be realized differs significantly with respect to the diameter of the nozzle utilized for the extrusion. This feasibility study demonstrated that the FDM technique is suitable to build accurate scaffold samples only in the cases where the strand diameter is close to the nozzle diameter. Conversely, when a large difference exists, large fabrication errors can be committed on the diameter of the filaments. In general, the scaffolds realized with the FDM technique were predicted to stimulate the formation of amounts of bone smaller than those that can be obtained with other regular beam-based scaffolds.
Language	English
Publishing date	2020-02-01
Publishing country	Switzerland
Document type	Journal Article
ZDB-ID	2487261-1
ISSN	1996-1944
ISSN	1996-1944
DOI	10.3390/ma13030648
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