A Low-Cost Method to Prepare Biocompatible Filaments with Enhanced Physico-mechanical Properties for FDM 3D Printing

2020 ◽  
Vol 18 ◽  
Author(s):  
Deck Khong Tan ◽  
Niko Münzenrieder ◽  
Mohammed Maniruzzaman ◽  
Ali Nokhodchi
Keyword(s):  
3D Printing ◽  
Low Cost ◽  
Fused Deposition Modelling ◽  
Processing Temperature ◽  
Melt Extrusion ◽  
Screw Extruder ◽  
Fused Deposition ◽  
Single Screw ◽  
Pharmaceutical Applications ◽  
Twin Screw

Background: Fused Deposition Modelling (FDM) 3D printing has received much interest as a fabrication method in the medical and pharmaceutical industry due to its accessibility and cost-effectiveness. A low-cost method to produce biocompatible and biodegradable filaments can improve the usability of FDM 3D printing for biomedical applications. Objectives: The feasibility of producing low-cost filaments suitable for FDM 3D printing via single screw and twin-screw hot melt extrusion was explored. Methods: A single-screw extruder and a twin-screw extruder were used to produce biocompatible filaments composed of varying concentrations of polyethylene glycol (PEG) at 10%, 20%, 30% w/w and polylactic acid (PLA) 90%, 80% and 70% w/w, respectively. DSC, TGA and FTIR were employed to investigate the effect of PEG on the PLA filaments. Results: The presence of PEG lowered the processing temperature of the formulation compositions via melt-extrusion, making it suitable for pharmaceutical applications. The use of PEG can lower the melting point of the PLA polymer to 170 °C, hence lowering the printing temperature. PEG can also improve the plasticity of the filaments, as the rupture strain of twinscrew extruded filaments increased up to 10-fold as compared to the commercial filaments. Advanced application of FTIR analysis confirmed the compatibility and miscibility of PEG with PLA. Conclusion: Twin-screw extrusion is more effective in producing a polymeric mixture of filaments as the mixing is more homogenous. The PEG/PLA filament is suitable to be used in 3D printing of medical or pharmaceutical applications such as medical implants, drug delivery systems, or personalised tablets.

scholarly journals Advanced Pharmaceutical Applications of Hot-Melt Extrusion Coupled with Fused Deposition Modelling (FDM) 3D Printing for Personalised Drug Delivery

Pharmaceutics ◽  
2018 ◽  
Vol 10 (4) ◽  
pp. 203 ◽  
Author(s):  
Deck Tan ◽  
Mohammed Maniruzzaman ◽  
Ali Nokhodchi
Keyword(s):  
3D Printing ◽  
Hot Melt Extrusion ◽  
Pharmaceutical Products ◽  
Fused Deposition Modelling ◽  
Melt Extrusion ◽  
3D Object ◽  
3D Printing Technology ◽  
Fused Deposition ◽  
Pharmaceutical Applications ◽  
Hot Melt

Three-dimensional printing, also known as additive manufacturing, is a fabrication process whereby a 3D object is created layer-by-layer by depositing a feedstock material such as thermoplastic polymer. The 3D printing technology has been widely used for rapid prototyping and its interest as a fabrication method has grown significantly across many disciplines. The most common 3D printing technology is called the Fused Deposition Modelling (FDM) which utilises thermoplastic filaments as a starting material, then extrudes the material in sequential layers above its melting temperature to create a 3D object. These filaments can be fabricated using the Hot-Melt Extrusion (HME) technology. The advantage of using HME to manufacture polymer filaments for FDM printing is that a homogenous solid dispersion of two or more pharmaceutical excipients i.e., polymers can be made and a thermostable drug can even be introduced in the filament composition, which is otherwise impractical with any other techniques. By introducing HME techniques for 3D printing filament development can improve the bioavailability and solubility of drugs as well as sustain the drug release for a prolonged period of time. The latter is of particular interest when medical implants are considered via 3D printing. In recent years, there has been increasing interest in implementing a continuous manufacturing method on pharmaceutical products development and manufacture, in order to ensure high quality and efficacy with less batch-to-batch variations of the pharmaceutical products. The HME and FDM technology can be combined into one integrated continuous processing platform. This article reviews the working principle of Hot Melt Extrusion and Fused Deposition Modelling, and how these two technologies can be combined for the use of advanced pharmaceutical applications.

scholarly journals Investigations for In-house prepared Biocompatible Feed Stock Filament of Fused Deposition Modelling: A Process Capability study

2019 ◽  
Vol 48 (1) ◽  
pp. 18-23
Author(s):  
Nishant Ranjan ◽  
Rupinder Singh ◽  
IPS Ahuja
Keyword(s):  
Control Charts ◽  
Low Cost ◽  
Process Capability ◽  
Dimensional Accuracy ◽  
Fused Deposition Modelling ◽  
Twin Screw Extrusion ◽  
Fused Deposition ◽  
Feed Stock ◽  
Screw Extrusion ◽  
Twin Screw

Fused deposition modelling (FDM) is one of the low cost additive manufacturing (AM) process. The feed stock filament of FDM is the only consumable in the process and by preparing (in-house) bio compatible feed stock filament the application domain can be increased. Some studies have reported the use of twin screw extrusion (TSE) process for preparation of bio compatible feed stock filament (comprising of polyvinyl chloride (PVC) and polypropylene (PP) and hydroxyapatite (HAp) particles) with improved mechanical, dimensional and thermal properties, for commercial FDM setup. But hitherto very less has been reported on process capability of in-house prepared biocompatible feed stock filament. In the present work statistical analysis (for tensile strength, hardness and dimensional accuracy) has been performed for investigations of process capability. The results have been also supported by control charts (X-chart and R-chart) based upon the best feedstock filament wire.

Investigating the Mechanical Behavior of 3D Printed PLA-Coco Coir Composites

2021 ◽  
Vol 1046 ◽  
pp. 125-132
Author(s):  
Paul Eric C. Maglalang ◽  
Blessie A. Basilia ◽  
Araceli Magsino Monsada
Keyword(s):  
Mechanical Properties ◽  
Particle Size ◽  
3D Printing ◽  
Fused Deposition Modelling ◽  
Coir Fiber ◽  
Fiber Concentration ◽  
Fused Deposition ◽  
Twin Screw ◽  
Raster Angle ◽  
Composite Filament

It is quite amazing that the use of 3D printing techniques, especially the Fused Deposition Modelling (FDM) has delivered such significance in terms of cost reduction, time saver features where a different variety of thermoplastic and composite materials (Biodegradable and Non-biodegradable) are well developed. Different sectors have continually developed natural organic materials that are also both structurally composite in nature. Similarly, the use of different fibers that are abundantly accessible and considered as renewable resources which can be optionally combined with other biodegradable materials is a great challenge through the use of the FDM printing method. The study aims to determine the effect of different particle size and raster angle at a certain fiber concentration which could affect the mechanical properties of the composite by developing a printable composite filament made of Polylactic Acid (PLA) and Coco Coir materials using a filament maker and FDM printer. The composite filament was fabricated and optimized using a twin-screw extruder and 3D Devo Filament maker. 3D printing of samples for mechanical testing was conducted using three (3) raster angles (45o, 60o, and 75o) and various particle sizes of coco coir fiber reinforcement in the PLA matrix. Results showed that the < 74μm particle size of the coco-coir exhibited a 24% and 175% increase in tensile strength and izod impact strength compared to the pure PLA at 60o and 75o raster angles, respectively. Likewise, the reinforcement of <149μm particle size coco coir at 45o raster angle contributes to an increase of 4.8% flexural and 176% compressive strength compared to pure PLA. The study concludes that there is an improvement in the mechanical properties of the PLA-Coco Coir composite at a certain particle size and raster angle in 3D printing.

scholarly journals A 3D Printed, Constriction-Resistive Sensor for the Detection of Ultrasonic Waves

2021 ◽  
Keyword(s):  
Structural Health Monitoring ◽  
3D Printing ◽  
Health Monitoring ◽  
Low Cost ◽  
Ultrasonic Waves ◽  
Fused Deposition Modelling ◽  
Fused Filament Fabrication ◽  
Engineering Structures ◽  
Structural Health ◽  
Fused Deposition

Abstract. Ultrasonic waves, either bulk waves or guided waves, are commonly used for non-destructive evaluation, for example in structural health monitoring. Traditional sensors for detecting ultrasonic waves include metallic strain gauges and piezoelectric ceramics. Recently piezoresistive nanocomposites have emerged as a promising sensor with high sensing range. In this paper, a constriction-resistive based sensor made from a graphene reinforced PLA filament is developed using a fused deposition modelling 3D printing approach as a novel type of ultrasonic sensor for structural health monitoring purposes. The sensor is made of very low-cost and recyclable thermoplastic material, which is lightweight and can be either directly printed onto the surface of various engineering structures, or embedded into the interior of a structure via fused filament fabrication 3D printing. These characteristics make this sensor a promising candidate compared to the traditional sensors in detecting ultrasonic waves for structural health monitoring. The printed sensors can detect ultrasonic signals with frequencies around 200 kHz, with good signal-to-noise ratio and sensitivity. When deployed between two adjacent printed tracks , and exploiting a novel kissing-bond mechanism, the sensor is capable of detecting ultrasonic waves. Several confirmatory experiments were carried out on this printed sensor to validate the capability of the printed sensor for structural health monitoring.

scholarly journals A Low-Cost Multi-Sensor Data Acquisition System for Fault Detection in Fused Deposition Modelling

Sensors ◽  
2022 ◽  
Vol 22 (2) ◽  
pp. 517
Author(s):  
Satish Kumar ◽  
Tushar Kolekar ◽  
Shruti Patil ◽  
Arunkumar Bongale ◽  
Ketan Kotecha ◽  
...  
Keyword(s):  
3D Printing ◽  
Data Acquisition ◽  
Low Cost ◽  
Data Acquisition System ◽  
Acquisition System ◽  
Sensor Data ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Sensor Data Acquisition

Fused deposition modelling (FDM)-based 3D printing is a trending technology in the era of Industry 4.0 that manufactures products in layer-by-layer form. It shows remarkable benefits such as rapid prototyping, cost-effectiveness, flexibility, and a sustainable manufacturing approach. Along with such advantages, a few defects occur in FDM products during the printing stage. Diagnosing defects occurring during 3D printing is a challenging task. Proper data acquisition and monitoring systems need to be developed for effective fault diagnosis. In this paper, the authors proposed a low-cost multi-sensor data acquisition system (DAQ) for detecting various faults in 3D printed products. The data acquisition system was developed using an Arduino micro-controller that collects real-time multi-sensor signals using vibration, current, and sound sensors. The different types of fault conditions are referred to introduce various defects in 3D products to analyze the effect of the fault conditions on the captured sensor data. Time and frequency domain analyses were performed on captured data to create feature vectors by selecting the chi-square method, and the most significant features were selected to train the CNN model. The K-means cluster algorithm was used for data clustering purposes, and the bell curve or normal distribution curve was used to define individual sensor threshold values under normal conditions. The CNN model was used to classify the normal and fault condition data, which gave an accuracy of around 94%, by evaluating the model performance based on recall, precision, and F1 score.

Development of PLA-HAp-CS-based biocompatible functional prototype: A case study

2018 ◽  
Vol 33 (3) ◽  
pp. 305-323 ◽  
Author(s):  
Nishant Ranjan ◽  
Rupinder Singh ◽  
IPS Ahuja
Keyword(s):  
3D Printing ◽  
Three Dimensional ◽  
Microscopic Analysis ◽  
Fused Deposition Modelling ◽  
Electron Microscopic ◽  
Dead Weight ◽  
Fused Deposition ◽  
Twin Screw ◽  
Functional Prototype

In this article, detailed procedure for the development of polylactic acid (PLA), hydroxyapatite (HAp) and chitosan (CS)-based biocompatible functional prototype has been outlined by using three-dimensional (3D) printing as a case study. The biocompatible composite-based feedstock filament (comprising of PLA-HAp-CS) has been prepared through twin-screw extruder (TSE) for open-source fused deposition modelling (FDM)-based 3D printer. This case study provides two-stage multifactor optimization: (a) for preparation of feedstock filament on TSE and (b) 3D printing on FDM based upon tensile and flexural samples. The results of study suggest that the best settings of input parameters for TSE are barrel temperature of 190°C, screw speed of 140 r/min and dead weight of 12 kg. Further, the optimized settings for FDM are layer thickness of 0.2 mm, deposition angle of 30/45° and infill density of 100%. The results have been supported by scanning electron microscopic analysis.

scholarly journals Pharmaceutical Applications of Hot-Melt Extrusion: Continuous Manufacturing, Twin-Screw Granulations, and 3D Printing

Pharmaceutics ◽  
2019 ◽  
Vol 11 (5) ◽  
pp. 218 ◽  
Author(s):  
Mohammed Maniruzzaman
Keyword(s):  
3D Printing ◽  
Hot Melt Extrusion ◽  
Continuous Manufacturing ◽  
Melt Extrusion ◽  
Pharmaceutical Applications ◽  
Twin Screw ◽  
Hot Melt

Recently, hot-melt extrusion (HME) techniques have been presented as innovative platforms to produce various pharmaceuticals [...]

Application of Fused Deposition Modelling (FDM) Method of 3D Printing in Drug Delivery

2017 ◽  
Vol 23 (3) ◽  
pp. 433-439 ◽  
Author(s):  
Jingjunjiao Long ◽  
Hamideh Gholizadeh ◽  
Jun Lu ◽  
Craig Bunt ◽  
Ali Seyfoddin
Keyword(s):  
Drug Delivery ◽  
3D Printing ◽  
Low Cost ◽  
Three Dimensional ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Accurate Dose ◽  
Drug Delivery Devices ◽  
3D Printing Technique

Three-dimensional (3D) printing is an emerging manufacturing technology for biomedical and pharmaceutical applications. Fused deposition modelling (FDM) is a low cost extrusion-based 3D printing technique that can deposit materials layer-by-layer to create solid geometries. This review article aims to provide an overview of FDM based 3D printing application in developing new drug delivery systems. The principle methodology, suitable polymers and important parameters in FDM technology and its applications in fabrication of personalised tablets and drug delivery devices are discussed in this review. FDM based 3D printing is a novel and versatile manufacturing technique for creating customised drug delivery devices that contain accurate dose of medicine( s) and provide controlled drug released profiles.

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