The feasibility of producing patient-specific acrylic cranioplasty implants with a low-cost 3D printer

OBJECT Commercially available, preformed patient-specific cranioplasty implants are anatomically accurate but costly. Acrylic bone cement is a commonly used alternative. However, the manual shaping of the bone cement is difficult and may not lead to a satisfactory implant in some cases. The object of this study was to determine the feasibility of fabricating molds using a commercial low-cost 3D printer for the purpose of producing patient-specific acrylic cranioplasty implants. METHODS Using data from a high-resolution brain CT scan of a patient with a calvarial defect posthemicraniectomy, a skull phantom and a mold were generated with computer software and fabricated with the 3D printer using the fused deposition modeling method. The mold was used as a template to shape the acrylic implant, which was formed via a polymerization reaction. The resulting implant was fitted to the skull phantom and the cranial index of symmetry was determined. RESULTS The skull phantom and mold were successfully fabricated with the 3D printer. The application of acrylic bone cement to the mold was simple and straightforward. The resulting implant did not require further adjustment or drilling prior to being fitted to the skull phantom. The cranial index of symmetry was 96.2% (the cranial index of symmetry is 100% for a perfectly symmetrical skull). CONCLUSIONS This study showed that it is feasible to produce patient-specific acrylic cranioplasty implants with a low-cost 3D printer. Further studies are required to determine applicability in the clinical setting. This promising technique has the potential to bring personalized medicine to more patients around the world.

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3D Printed Fully Recycled TiO2-Polystyrene Nanocomposite Photocatalysts for Use against Drug Residues

Nanomaterials ◽

10.3390/nano10112144 ◽

2020 ◽

Vol 10 (11) ◽

pp. 2144

Author(s):

Maria Sevastaki ◽

Mirela Petruta Suchea ◽

George Kenanakis

Keyword(s):

Tio2 Nanoparticles ◽

Large Scale ◽

Fused Deposition Modeling ◽

Low Cost ◽

Real Life ◽

3D Printer ◽

Alternative Route ◽

Fused Deposition ◽

Deposition Modeling ◽

3D Printed

In the present work, the use of nanocomposite polymeric filaments based on 100% recycled solid polystyrene everyday products, enriched with TiO2 nanoparticles with mass concentrations up to 40% w/w, and the production of 3D photocatalytic structures using a typical fused deposition modeling (FDM)-type 3D printer are reported. We provide evidence that the fabricated 3D structures offer promising photocatalytic properties, indicating that the proposed technique is indeed a novel low-cost alternative route for fabricating large-scale photocatalysts, suitable for practical real-life applications.

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Low Cost with Vibration Controlled Efficient Fused Deposition Modeling

International Journal of Engineering and Advanced Technology - Regular Issue ◽

10.35940/ijeat.f8417.088619 ◽

2019 ◽

Vol 8 (6) ◽

pp. 1690-1694

Keyword(s):

Fused Deposition Modeling ◽

Low Cost ◽

Fused Deposition Modelling ◽

3D Printer ◽

Body Parts ◽

Fused Deposition ◽

Rigid Frame ◽

Innovative System ◽

Industrial Unit ◽

Cost Efficient

Fused Deposition Modelling (FDM) is an innovative system that can create necessary items and are significant to generate distinctive styles of articles, in unusual supplies, completely from the uniform system. FDM machine can build fair model everything from stoneware to synthetic dolls, iron machine parts, decorative chocolate cakes or regular human body parts. FDM can supersede conventional factory industrial unit with only machinery, simply like printing press swapped by bottles of ink. Nowadays these machines are available at higher costs and are used only in industrial areas. With technology available and the material used in these machines proposes a system that sparks upon making a low cost-efficient machine and materials by designing a rigid frame for the 3D printer. The result shows low cost 3D printer prototype of FDM machine and the vibration analysis with various speed at various stages for the product outcome

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Design and Validation of an Open Source 3D Printer Based on Digital Ultraviolet Light Processing (DLP), for the Improvement of Traditional Artistic Casting Techniques for Microsculptures

Applied Sciences ◽

10.3390/app11073197 ◽

2021 ◽

Vol 11 (7) ◽

pp. 3197

Author(s):

Jose Luis Saorin ◽

Manuel Drago Diaz-Alemán ◽

Jorge De la Torre-Cantero ◽

Cecile Meier ◽

Ithaisa Pérez Conesa

Keyword(s):

Open Source ◽

Ultraviolet Light ◽

Fused Deposition Modeling ◽

Liquid Crystal Display ◽

Low Cost ◽

3D Printer ◽

Digital Light Processing ◽

Fused Deposition ◽

3D Printers ◽

Deposition Modeling

The adoption of open-source digital manufacturing technologies in small art workshops may improve their competitiveness. Pieces modeled by computer and made with FDM (Fused Deposition Modeling) 3D printers that use PLA (polylactic acid) can be implemented in the procedures of artistic casting. However, models printed by PLA are limited to approximate minimum sizes of 3 cm, and the optimal layer height resolution is 0.1 mm. These sizes and resolutions are not suitable for creating microsculptures used, in many cases, in jewelry. An alternative to solve this limitation, is to use a DMLS (Direct Metal Laser Sintering) 3D printer. However, due to its high cost, it is a technology that is difficult to introduce in small artistic foundries. This work detailed the design and validation of a DLP (Digital Light Processing) 3D printer, using backlit LCD (Liquid Crystal Display) screens with ultraviolet light. Its development is totally “open source” and is proposed as a kit made up of electronic components, based on Arduino and easy to access mechanical components in the market. Most parts can be manufactured in low cost FDM (Fused Deposition Modeling) 3D printers. The result is an affordable, high resolution (0.021 mm), and open-design printer that can be implemented in artistic contexts.

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3D-printed pediatric temporal bone models for surgical training: a patient-specific and low-cost alternative

Journal of 3D Printing in Medicine ◽

10.2217/3dp-2019-0011 ◽

2019 ◽

Vol 3 (3) ◽

pp. 135-143

Author(s):

Juan C Ospina ◽

Alejandro Fandiño ◽

Santiago Hernández ◽

Luis F Uriza ◽

Diego Aragonéz ◽

...

Keyword(s):

Temporal Bone ◽

Surgical Training ◽

Fused Deposition Modeling ◽

Surgical Simulation ◽

Low Cost ◽

Patient Specific ◽

Fused Deposition ◽

Deposition Modeling ◽

3D Printed ◽

Temporal Bones

Aim: To determine the usefulness of low-cost 3D-printed pediatric temporal bone models and to define if they could be used as a tool for large-scale surgical training based on their affordability. Materials & methods: Prototypes of a pediatric temporal bone were printed using fused deposition modeling 3D printing technique. The prototypes were drilled. The surgical simulation experience was registered by means of a Likert scale questionnaire. Results: The prototypes adequately simulated a cadaveric temporal bone. The costs associated with production were low compared with other commercial models making it a cost-effective alternative for a temporal bone laboratory. Conclusion: Printed temporal bones created by means of fused deposition modeling are useful for surgical simulation and training in otolaryngology, and it is possible to achieve detailed low-cost models.

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Three-dimensional printing versus conventional machining in the creation of a meatal urethral dilator: a cost and mechanical strength analysis

10.21203/rs.2.21033/v1 ◽

2020 ◽

Author(s):

Michael Yue-Cheng Chen ◽

Jacob Skewes ◽

Ryan Daley ◽

Maria Ann Woodruff ◽

Nicholas John Rukin

Keyword(s):

3D Printing ◽

Low Cost ◽

Three Dimensional ◽

Patient Specific ◽

Strength Analysis ◽

3D Printer ◽

Fused Deposition ◽

3D Printed ◽

The Cost ◽

Conventional Machining

Abstract Background Three-dimensional (3D) printing is a promising technology in medicine. Low-cost 3D printing options are accessible but the limitations are often poorly understood. We aim to compare fused deposition modelling (FDM), the most common and low cost 3D printing technique, with selective laser sintering (SLS) and conventional machining techniques in manufacturing meatal urethral dilators which were recently removed from the Australian market.Methods A meatal urethral dilator was designed using computer-aided design (CAD). The dilator was 3D printed vertically orientated on a low cost FDM 3D printer in polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS). It was also 3D printed horizontally orientated in ABS on a high-end FDM 3D printer with soluble support material, as well as on a SLS 3D printer in medical nylon. The dilator was also machined in medical stainless steel using a lathe. All dilators were tested mechanically in a custom rig by hanging calibrated weights from the handle until the dilator snapped.Results The horizontally printed ABS dilator experienced failure at a greater load than the vertically printed PLA and ABS dilators respectively (503g vs 283g vs 163g, p < 0.001). The SLS nylon dilator did not fail but began to bend and deformed at around 5,000g of pressure. The steel dilator did not bend even at 10,000g of pressure. The cost per dilator is highest for the steel dilator if assuming a low quantity of five at 98 USD, but this decreases to 30 USD for a quantity of 1000. In contrast, the cost for the SLS dilator is 33 USD for a quantity of five but relatively unchanged at 27 for a quantity of 1000.Conclusions SLS and conventional machining created clinically functional meatal dilators but low-cost FDM printing could not. We suggest that at the current time 3D printing is not a replacement for conventional manufacturing techniques which are still the most reliable way to produce large quantities of parts with a simple geometry such as the meatal dilator. 3D printing is best used for patient-specific parts, prototyping or manufacturing complex parts that have additional functionality that cannot be achieved with conventional machining methods.

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The feasibility of printing polylactic acid-nanohydroxyapatite composites using a low-cost fused deposition modeling 3D printer

Journal of Applied Polymer Science ◽

10.1002/app.44656 ◽

2016 ◽

Vol 134 (13) ◽

Cited By ~ 39

Author(s):

Carola Esposito Corcione ◽

Francesca Gervaso ◽

Francesca Scalera ◽

Francesco Montagna ◽

Alessandro Sannino ◽

...

Keyword(s):

Polylactic Acid ◽

Fused Deposition Modeling ◽

Low Cost ◽

3D Printer ◽

Fused Deposition ◽

Deposition Modeling

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Development of Fused Deposition Modeling Using Five-Axis Machine and Printing Methods

10.21203/rs.3.rs-1067289/v1 ◽

2021 ◽

Author(s):

Haiguang zhang ◽

Kunlong zhao ◽

Di Liu ◽

Qingxi Hu ◽

Herfried Lammer

Keyword(s):

Degrees Of Freedom ◽

Fused Deposition Modeling ◽

Low Cost ◽

Industrial Applications ◽

3D Printer ◽

Lightweight Structures ◽

Fused Deposition ◽

3D Geometry ◽

Deposition Modeling ◽

Five Axis

Abstract Fused deposition modeling (FDM) is one of most widely used 3D printing technologies due to inexpensive equipment and materials, and easy to operate. FDM forms a 3D geometry by slicing a model along the XY-plane and assembling the resulting individual layers along the Z-axis, with extruded thermoplastic filaments. FDM printed parts usually need supporting structures, have stair step effect, and unfavorable mechanical properties. In order to address these deficiencies, a five-axis 3D printer and corresponding printing methods are proposed and developed in this paper. The 3D printer was designed five degrees of freedom through adding a platform that can rotate and swing. Based on the obtained results from different case studies, the discussed machine and methods could become more significant in industrial applications such as low cost, fabricating parts with better surface quality and lightweight structures.

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Comparison on Dimensional Accuracy Using a Newly Developed Nozzle for Open-Source 3D Printer

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.859.15 ◽

2016 ◽

Vol 859 ◽

pp. 15-19 ◽

Cited By ~ 2

Author(s):

Nor Aiman Sukindar ◽

Mohd Khairol Anuar Mohd Ariffin ◽

B.T. Hang Tuah bin Baharudin ◽

Che Nor Aiza Jaafar ◽

Mohd Idris Shah Ismail

Keyword(s):

Open Source ◽

Fused Deposition Modeling ◽

Low Cost ◽

Dimensional Accuracy ◽

3D Printer ◽

Constant Heat ◽

New Era ◽

Fused Deposition ◽

Deposition Modeling ◽

Increasing Demand

Fused Deposition Modeling (FDM) or also known as RepRap (Replicating Rapid Prototyper) is a technology that is synonym with 3D printing. This technology has entered a new era with an increasing demand among the community. It has grown commercially in the market of open-source system and it is relatively low cost. Many efforts have been put towards the development of the system in both hardware and software to increase the quality and the performance. The research highlights the development of a new nozzle to evaluate the performance on dimensional accuracy in comparison to the original nozzle. The nozzle emphasizes the die angle for the polylactic acid (PLA) material, the liquefier design which provide constant heat in the liquefier chamber, as well as insulator for the liquefier using highly insulated material. The dimensional accuracies of both nozzles were compared where the result showed that the new nozzle provided better accuracy and stability on the extruding PLA material.

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An Update on the Use of Alginate in Additive Biofabrication Techniques

Current Pharmaceutical Design ◽

10.2174/1381612825666190423155835 ◽

2019 ◽

Vol 25 (11) ◽

pp. 1249-1264 ◽

Cited By ~ 2

Author(s):

Amoljit Singh Gill ◽

Parneet Kaur Deol ◽

Indu Pal Kaur

Keyword(s):

Fused Deposition Modeling ◽

Low Cost ◽

Selective Laser Sintering ◽

Layer By Layer ◽

Three Dimension ◽

Anionic Polymer ◽

Fused Deposition ◽

The Status ◽

Deposition Modeling ◽

Extrusion Printing

Background: Solid free forming (SFF) technique also called additive manufacturing process is immensely popular for biofabrication owing to its high accuracy, precision and reproducibility. Method: SFF techniques like stereolithography, selective laser sintering, fused deposition modeling, extrusion printing, and inkjet printing create three dimension (3D) structures by layer by layer processing of the material. To achieve desirable results, selection of the appropriate technique is an important aspect and it is based on the nature of biomaterial or bioink to be processed. Result & Conclusion: Alginate is a commonly employed bioink in biofabrication process, attributable to its nontoxic, biodegradable and biocompatible nature; low cost; and tendency to form hydrogel under mild conditions. Furthermore, control on its rheological properties like viscosity and shear thinning, makes this natural anionic polymer an appropriate candidate for many of the SFF techniques. It is endeavoured in the present review to highlight the status of alginate as bioink in various SFF techniques.

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Quality Control in 3D Printing: Accuracy Analysis of 3D-Printed Models of Patient-Specific Anatomy

Materials ◽

10.3390/ma14041021 ◽

2021 ◽

Vol 14 (4) ◽

pp. 1021

Author(s):

Bernhard Dorweiler ◽

Pia Elisabeth Baqué ◽

Rayan Chaban ◽

Ahmed Ghazy ◽

Oroa Salem

Keyword(s):

Wall Thickness ◽

Large Scale ◽

Fused Deposition Modeling ◽

Vascular Anatomy ◽

3D Models ◽

Patient Specific ◽

Stl File ◽

Fused Deposition ◽

3D Printed ◽

The Mean

As comparative data on the precision of 3D-printed anatomical models are sparse, the aim of this study was to evaluate the accuracy of 3D-printed models of vascular anatomy generated by two commonly used printing technologies. Thirty-five 3D models of large (aortic, wall thickness of 2 mm, n = 30) and small (coronary, wall thickness of 1.25 mm, n = 5) vessels printed with fused deposition modeling (FDM) (rigid, n = 20) and PolyJet (flexible, n = 15) technology were subjected to high-resolution CT scans. From the resulting DICOM (Digital Imaging and Communications in Medicine) dataset, an STL file was generated and wall thickness as well as surface congruency were compared with the original STL file using dedicated 3D engineering software. The mean wall thickness for the large-scale aortic models was 2.11 µm (+5%), and 1.26 µm (+0.8%) for the coronary models, resulting in an overall mean wall thickness of +5% for all 35 3D models when compared to the original STL file. The mean surface deviation was found to be +120 µm for all models, with +100 µm for the aortic and +180 µm for the coronary 3D models, respectively. Both printing technologies were found to conform with the currently set standards of accuracy (<1 mm), demonstrating that accurate 3D models of large and small vessel anatomy can be generated by both FDM and PolyJet printing technology using rigid and flexible polymers.

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