Predictive Modeling and Experimental Verification of Temperature and Concentration in Rapid Freeze Prototyping With Support Material

2009 ◽  
Vol 131 (4) ◽  
Author(s):  
Frances D. Bryant ◽  
Ming C. Leu
Keyword(s):  
Prediction Model ◽  
Predictive Modeling ◽  
Solid Freeform Fabrication ◽  
Three Dimensional ◽  
Support Material ◽  
Temperature Prediction ◽  
Freeform Fabrication ◽  
Support Materials ◽  
Rapid Freeze Prototyping ◽  
Concentration Prediction

Rapid freeze prototyping is a solid freeform fabrication method that uses water freezing into ice as the build material. Each layer of geometry is deposited and allowed to freeze before the next layer is added in order to additively create a three-dimensional ice part. A sacrificial support material is needed for the fabrication of complex ice parts. Identifying a suitable support material and understanding the interaction between the build and support materials is the motivation behind this study. A temperature prediction model and a concentration prediction model are presented. Experimental results have been obtained to validate these models.

Modeling of Spatially Controlled Biomolecules in Three-Dimensional Porous Alginate Structures

2010 ◽  
Vol 4 (4) ◽  
Author(s):  
Ibrahim T. Ozbolat ◽  
Bahattin Koc
Keyword(s):  
Computer Aided Design ◽  
Solid Freeform Fabrication ◽  
Imaging Techniques ◽  
Release Kinetics ◽  
Three Dimensional ◽  
Control Release ◽  
Stochastic Approach ◽  
Distribution Characteristics ◽  
Porous Structures ◽  
Freeform Fabrication

This paper presents a computer-aided design (CAD) of 3D porous tissue scaffolds with spatial control of encapsulated biomolecule distributions. A localized control of encapsulated biomolecule distribution over 3D structures is proposed to control release kinetics spatially for tissue engineering and drug release. Imaging techniques are applied to explore distribution of microspheres over porous structures. Using microspheres in this study represents a framework for modeling the distribution characteristics of encapsulated proteins, growth factors, cells, and drugs. A quantification study is then performed to assure microsphere variation over various structures under imaging analysis. The obtained distribution characteristics are mimicked by the developed stochastic modeling study of microsphere distribution over 3D engineered freeform structures. Based on the stochastic approach, 3D porous structures are modeled and designed in CAD. Modeling of microsphere and encapsulating biomaterial distribution in this work helps develop comprehensive modeling of biomolecule release kinetics for further research. A novel multichamber single nozzle solid freeform fabrication technique is utilized to fabricate sample structures. The presented methods are implemented and illustrative examples are presented in this paper.

A Computational Design Framework for a Rapid Solid Freeform Fabrication Process

2000 ◽  
Author(s):  
Deepesh Khandelwal ◽  
T. Kesavadas
Keyword(s):  
Solid Freeform Fabrication ◽  
Optimization Technique ◽  
Three Dimensional ◽  
Computational Design ◽  
Freeform Fabrication ◽  
3D Cad ◽  
Build Time ◽  
Cad Models ◽  
Efficient Machine ◽  
Novel Concept

Abstract Solid Freeform Fabrication (SFF) techniques in recent years have shown tremendous promise in reducing the design time of products. This technique enables designers to get three-dimensional physical prototypes from 3D CAD models. Although SFF has gained popularity, the manufacturing time and cost have limited its use to small and medium sized parts. In this paper we have proposed a novel concept for rapidly building SFF parts by inserting prefabricated inserts into the fabricated part. A computational algorithm was developed for determining ideal placement of inserts/cores in the CAD model of the part being prototyped using a heuristic optimization technique called Simulated Annealing. This approach will also allow the designers to build multi-material prototypes using the Rapid Prototyping (RP) technique. By using cheaper pre-fabricates instead of costly photopolymers, the production cost of the SFFs can be reduced. Additionally it will also reduce build time, resulting in efficient machine utilization.

Direct Freeform Fabrication Technique for Bio-Manufacturing of Pre-Seeded, Spatially Heterogeneous, Anatomically-Shaped Alginate Hydrogel Implants

2005 ◽  
Author(s):  
Daniel L. Cohen ◽  
Evan Malone ◽  
Hod Lipson ◽  
Lawrence J. Bonassar
Keyword(s):  
Tissue Engineering ◽  
Solid Freeform Fabrication ◽  
Crosslinking Agent ◽  
Three Dimensional ◽  
Patient Specific ◽  
Efficient Production ◽  
Alginate Hydrogel ◽  
Freeform Fabrication ◽  
Patient Specific Implants ◽  
Multiple Material

A major challenge in orthopaedic tissue engineering is the generation of cell-seeded implants with structures that mimic native tissue, both in terms of anatomic geometries and intratissue cell distributions. By combining the strengths of injection molding tissue engineering with those of Solid Freeform Fabrication (SFF), three-dimensional pre-seeded implants were fabricated without custom-tooling, enabling efficient production of patient-specific implants. The incorporation of SFF technology also enables the fabrication of geometrically complex, multiple-material implants with spatially heterogeneous cell distributions that could not otherwise be produced. Using a custom-built robotic SFF platform and gel deposition tools, alginate hydrogel was used with calcium sulfate as a crosslinking agent to produce pre-seeded living implants of arbitrary geometries. The process was determined to be sterile and viable at 94±5%. The GAG production was found to be about half that of a similarly molded samples. The compressive elastic modulus was determined to be 1.462±0.113 kPa.

Development of HA-PLGA Scaffold Encapsulating Intact BMP-2 Using Solid Freeform Fabrication Technology

2011 ◽  
Author(s):  
Jin-Hyung Shim ◽  
Jong Young Kim ◽  
Kyung Shin Kang ◽  
Jung Kyu Park ◽  
Sei Kwang Hahn ◽  
...  
Keyword(s):  
Tissue Engineering ◽  
Bone Regeneration ◽  
Porous Scaffold ◽  
Solid Freeform Fabrication ◽  
Three Dimensional ◽  
Porous Scaffolds ◽  
Prolonged Release ◽  
Cellular Activity ◽  
Freeform Fabrication

Tissue engineering is an interdisciplinary field that focuses on restoring and repairing tissues or organs. Cells, scaffolds, and biomolecules are recognized as three main components of tissue engineering. Solid freeform fabrication (SFF) technology is required to fabricate three-dimensional (3D) porous scaffolds to provide a 3D environment for cellular activity. SFF technology is especially advantageous for achieving a fully interconnected, porous scaffold. Bone morphogenic protein-2 (BMP-2), an important biomolecule, is widely used in bone tissue engineering to enhance bone regeneration activity. However, methods for the direct incorporation of intact BMP-2 within 3D scaffolds are rare. In this work, 3D porous scaffolds with poly(lactic-co-glycolic acid) chemically grafted hyaluronic acid (HA-PLGA), in which intact BMP-2 was directly encapsulated, were successfully fabricated using SFF technology. BMP-2 was previously protected by poly(ethylene glycol) (PEG), and the BMP-2/PEG complex was incorporated in HA-PLGA using an organic solvent. The HAPLGA/PEG/BMP-2 mixture was dissolved in chloroform and deposited via a multi-head deposition system (MHDS), one type of SFF technology, to fabricate a scaffold for tissue engineering. An additional air blower system and suction were installed in the MHDS for the solvent-based fabrication method. An in vitro evaluation of BMP-2 release was conducted, and prolonged release of intact BMP-2, for up to 28 days, was confirmed. After confirmation of advanced proliferation of pre osteoblasts, a superior differentiation effect of the HA-PLGA/PEG/BMP-2 scaffold was validated by measuring high expression levels of bone-specific markers, such as alkaline phosphatase (ALP) and osteocalcin (OC). We show that our solvent-based fabrication is a non-toxic method for restoring cellular activity. Moreover, the HAPLGA/PEG/BMP-2 scaffold was effective for bone regeneration.

A Novel Three-Dimensional Direct Controlled Cell Assembling System

2013 ◽  
Vol 652-654 ◽  
pp. 2079-2085
Author(s):  
Yu Li ◽  
Lei Zhang ◽  
Chang Yong Liu ◽  
Yu Zhao ◽  
Wei Sun
Keyword(s):  
Experimental Study ◽  
Modular Design ◽  
Design Method ◽  
Solid Freeform Fabrication ◽  
Three Dimensional ◽  
Freeform Fabrication ◽  
Heterogeneous Object ◽  
Continuous Deposition ◽  
Deposition Mode ◽  
Cell Assembling

Solid freeform fabrication (SFF) technology has been widely used to fabricate three-dimensional (3D) cell constructs. As multi-cell construct is a heterogeneous object (He-Object), it is a trend of biomanufacturing to use SFF technology to fabricate multi-cell constructs. In this paper, a novel multi-nozzle deposition system, called as 3D direct controlled cell assembling (CA) system, was developed to fabricate 3D multi-cell constructs. The developed system design was demand-oriented and applied functional modular design method. As the key part of this system, the multi-nozzle system was designed and described in details. Experimental study was conducted and results showed that the system could meet the requirements of the process and be used to fabricate complex 3D cell constructs. By comparison, the developed system could precisely deposite biomaterials with high viscocity and form constructs with big size in continuous deposition mode.

Successive Deposition of Metals in Solid Freeform Fabrication Processes, Part 1: Thermomechanical Models of Layers and Droplet Columns

2000 ◽  
Vol 123 (4) ◽  
pp. 623-631 ◽  
Author(s):  
R. K. Chin ◽  
J. L. Beuth ◽  
C. H. Amon
Keyword(s):  
Residual Stress ◽  
Temporal Evolution ◽  
Solid Freeform Fabrication ◽  
Three Dimensional ◽  
One Dimensional ◽  
Freeform Fabrication ◽  
Stress Effects ◽  
Levels Of Detail ◽  
Induced Tolerance ◽  
Thick Layers

Solid Freeform Fabrication (SFF) processes allow the automated building of three-dimensional shapes by successively depositing material in layers. Residual stress-induced tolerance losses are principal concerns in using these processes to create functional parts. Thermomechanical models of temperatures and stresses are presented, which are relevant to controlling residual stress effects in SFF processes. Models are applied to a particular SFF process; however, insights and conclusions are applicable to a large number of related processes. The temporal evolution of temperatures and stresses is investigated at two levels of detail. The successive deposition of layers of material is investigated first using one-dimensional simulations, approximating the build-up of residual stress in a multi-layered part. The successive deposition of a column of molten metal droplets (a technique used to create thick layers) is then modeled using two-dimensional axisymmetric simulations. Insights are given into process changes that can minimize residual stress-related effects in manufactured parts, including part constraint and localized preheating near the point of deposition. Results for thermomechanical interactions between droplets deposited in a column provide the foundation for studying interactions between adjacently deposited droplets, which is addressed in Part 2.

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