Multi-Material 3D Printing of a Customized Sports Mouth Guard: Proof-of-Concept Clinical Case

A multilayer mouth guard is known to have the best protective performance. However, its manufacturing in a digital workflow may be challenging with regards to virtual design and materialization. The present case demonstrates a pathway to fabricate a multilayer individualized mouth guard in a fully digital workflow, which starts with intraoral scanning. A free-form CAD software was used for the virtual design. Two various CAM techniques were used, including Polyjet 3D printing of rubber-like soft material and silicone printing using Drop-on-Demand technique. For both methods the outer layer was manufactured from more rigid materials to facilitate its protective function; the inner layer was printed from a softer material to aid a better adaptation to mucosa and teeth. Both 3D printed multilayer mouth guards showed a clinically acceptable fit and were met with patient appraisal. Their protective capacities must be evaluated in further clinical studies.

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3D-printed devices for continuous-flow organic chemistry

Beilstein Journal of Organic Chemistry ◽

10.3762/bjoc.9.109 ◽

2013 ◽

Vol 9 ◽

pp. 951-959 ◽

Cited By ~ 110

Author(s):

Vincenza Dragone ◽

Victor Sans ◽

Mali H Rosnes ◽

Philip J Kitson ◽

Leroy Cronin

Keyword(s):

Organic Chemistry ◽

3D Printing ◽

Continuous Flow ◽

Flow Chemistry ◽

Flow Cell ◽

Proof Of Concept ◽

Time Analysis ◽

Real Time Analysis ◽

Custom Made ◽

3D Printed

We present a study in which the versatility of 3D-printing is combined with the processing advantages of flow chemistry for the synthesis of organic compounds. Robust and inexpensive 3D-printed reactionware devices are easily connected using standard fittings resulting in complex, custom-made flow systems, including multiple reactors in a series with in-line, real-time analysis using an ATR-IR flow cell. As a proof of concept, we utilized two types of organic reactions, imine syntheses and imine reductions, to show how different reactor configurations and substrates give different products.

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Dental 3D-Printing: Transferring Art from the Laboratories to the Clinics

Polymers ◽

10.3390/polym13010157 ◽

2021 ◽

Vol 13 (1) ◽

pp. 157

Author(s):

Sangeeth Pillai ◽

Akshaya Upadhyay ◽

Parisa Khayambashi ◽

Imran Farooq ◽

Hisham Sabri ◽

...

Keyword(s):

3D Printing ◽

Clinical Success ◽

Three Dimensional ◽

Digital Workflow ◽

Dental Clinics ◽

Current Trends ◽

The Face ◽

Treatment Plans ◽

Versatile Technique ◽

3D Printed

The rise of three-dimensional (3D) printing technology has changed the face of dentistry over the past decade. 3D printing is a versatile technique that allows the fabrication of fully automated, tailor-made treatment plans, thereby delivering personalized dental devices and aids to the patients. It is highly efficient, reproducible, and provides fast and accurate results in an affordable manner. With persistent efforts among dentists for refining their practice, dental clinics are now acclimatizing from conventional treatment methods to a fully digital workflow to treat their patients. Apart from its clinical success, 3D printing techniques are now employed in developing haptic simulators, precise models for dental education, including patient awareness. In this narrative review, we discuss the evolution and current trends in 3D printing applications among various areas of dentistry. We aim to focus on the process of the digital workflow used in the clinical diagnosis of different dental conditions and how they are transferred from laboratories to clinics. A brief outlook on the most recent manufacturing methods of 3D printed objects and their current and future implications are also discussed.

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Assessment of the reproducibility and precision of milling and 3D printing surgical guides

BMC Oral Health ◽

10.1186/s12903-020-01362-6 ◽

2021 ◽

Vol 21 (1) ◽

Author(s):

Sueli Mukai ◽

Eduardo Mukai ◽

José Arnaldo Santos-Junior ◽

Jamil Awad Shibli ◽

Marcelo Faveri ◽

...

Keyword(s):

3D Printing ◽

Virtual Model ◽

Virtual Design ◽

Surgical Guides ◽

Technology Advancement ◽

Significant Difference ◽

Kolmogorov Smirnov ◽

3D Printed ◽

Test For Normality ◽

Smirnov Test

Abstract Background Technology advancement has rising in the past decade and brought several innovations and improvements. In dentistry, this advances provided more comfortable and quick procedures to both the patient and the dental surgeon, generating less predictability in the final result. Several techniques has been developed for the preparation of surgical guides aiming at the optimization of surgical procedures. The present study aimed to evaluate the reproducibility and precision of two types of surgical guides obtained using 3D printing and milling methods. Methods A virtual model was developed that allowed the virtual design of milled (n = 10) or 3D printed (n = 10) surgical guides. The surgical guides were digitally oriented and overlapped on the virtual model. For the milling guides, the Sirona Dentsply system was used, while the 3D printing guides were produced using EnvisionTEC’s Perfactory P4K Life Series 3D printer and E-Guide Tint, a biocompatible Class I certified material. The precision and trueness of each group during overlap were assessed. The data were analyzed with GraphPad software using the Kolmogorov–Smirnov test for normality and Student’s t test for the variables. Results The Kolmogorov–Smirnov test showed a normal distribution of the data. Comparisons between groups showed no statistically significant differences for trueness (p = 0.529) or precision (p = 0.3021). However, a significant difference was observed in the standard deviation of mismatches regarding accuracy from the master model (p < 0.0001). Conclusions Within the limits of this study, surgical guides fabricated by milling or prototyped processes achieved similar results.

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Micro injection molding of individualised implants using 3D printed molds manufactured via digital light processing

Current Directions in Biomedical Engineering ◽

10.1515/cdbme-2021-2101 ◽

2021 ◽

Vol 7 (2) ◽

pp. 399-402

Author(s):

Robert Mau ◽

Gábor Jüttner ◽

Ziwen Gao ◽

Farnaz Matin ◽

Dorian Alcacer Labrador ◽

...

Keyword(s):

3D Printing ◽

Injection Molding ◽

Round Window ◽

Free Form ◽

Micro Injection Molding ◽

Digital Light Processing ◽

Liquid Silicone ◽

3D Printed ◽

Round Window Niche ◽

Micro Implants

Abstract Here, we demonstrate a manufacturing process for individualised, small-sized implant prototypes. Our process is promising for the manufacturing of drug-releasing (micro)implants to be implanted in the round window niche (RWN-I, solid body, free-form-shaped design, 1.1 x 2.7 x 3.1 mm) and for frontal neo-ostium implants (FO-I, tube-like design, length ~ 7 mm, Ø ~ 2-6 mm) for frontal sinus drainage. Implant prototypes are manufactured using micro injection molding (μIM). We use digital light processing (DLP) as a 3D printing technique for rapid tooling of accurate molds for the μIM process. A common acrylate-based photopolymer for stiff and high-detailed modelling but with low head deflection temperature of HDT = 60.5 °C is used for DLP 3D printing of the molds. The molds were 3D printed with a layer height of 50 μm in about 20 min (RWN-I) and 60 min (FO-I). For μIM investigations, we use liquid silicone rubber (LSR) as a biocompatible and medically relevant material. Micro injection molding of LSR was investigated using mold temperatures between Tmold = 110 °C (long tcuring ~ 2 h) up to Tmold = 160 °C (short tcuring ~ 5 min). As a result, small-sized, complex-shaped implant prototypes of LSR can be successfully manufactured via μIM using high Tmold = 160 °C and short curing time. DLP 3D printing material with relative low HDT = 60.5 °C was suitable for μIM. There is no significant wear of the molds, when used for a low number of μIM cycles (n ~ 8). Design of metal mold housing has to be suitable (perfect fit of mold, no cavities facing the molds surface for prevention of thermal expansion of mold into cavities).

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Accessing axis : exploring design coginition from visual and haptic experiences as an apparel designer in digital 3d imaging using 3d printing technology

10.32469/10355/57783 ◽

2015 ◽

Author(s):

◽

Lushan Sun

Keyword(s):

3D Printing ◽

Design Process ◽

Digital Fabrication ◽

Apparel Design ◽

Virtual Design ◽

Printing Technology ◽

3D Printing Technology ◽

3D Cad ◽

Hands On ◽

3D Printed

Despite the rise of 3D printing technology in recent years, the novel technology has not yet heavily expanded to the realm of textile and apparel design. Although 3D printed design explorations have been unique and successful, the information shared only pertains to unique garment silhouettes or materials applied as oppose the insights into the specific 3D CAD process, which is the core of such digital fabrication methods. Following the Mutual Shaping of Technology framework, this study zoomed in on the ways for traditional apparel designers transition into the digital 3D modeling process from the visual and haptic cognitive aspects. This investigation involved a focus group study with 10 participants who are 3D CAD practitioners with hands-on object making backgrounds. The group study outcomes further contributed to the strategy that was then utilized in an independent case study involving studio practice and the development of a 3D printed wearable garment. The results from this exploratory study suggest that the transition from hands-on to digital modeling is a rather challenging process and relies heavily on tacit knowledge and the combination of object and spatial visualization skills interpreted in the forms of visual and haptic memory in order to develop an efficient workflow in the digital design process. The findings of this study are of great value in understanding the cognitive nature of the apparel designer's virtual design process in order to reflect on the current design curriculum. This study also is of importance to the future 3D CAD program interface design for both apparel and non-apparel design practice.

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Inkjet 3D Printed MEMS Vibrational Electromagnetic Energy Harvester

Energies ◽

10.3390/en13112800 ◽

2020 ◽

Vol 13 (11) ◽

pp. 2800 ◽

Cited By ~ 1

Author(s):

Bartosz Kawa ◽

Krzysztof Śliwa ◽

Vincent Lee ◽

Qiongfeng Shi ◽

Rafał Walczak

Keyword(s):

3D Printing ◽

Permanent Magnet ◽

Output Power ◽

Energy Harvester ◽

Three Dimensional ◽

Virtual Design ◽

Resonant Frequencies ◽

Hybrid Energy ◽

Electromechanical Energy ◽

3D Printed

Three-dimensional (3D) printing is a powerful tool that enables the printing of almost unlimited geometry in a few hours, from a virtual design to a real structure. In this paper, we present a micro-electromechanical energy harvester that utilized a 3D printed micromechanical structure combined with a miniature permanent magnet and a microelectronic coil towards a hybrid electromagnetic vibrational hybrid energy harvester. Various micromechanical structure geometries were designed, printed, and tested. The characteristic dimensions of the springs were from 200 μm to 400 μm and the total volume of the devices was below 1 cm3. The resonant frequencies (95–340 Hz range), as well as bandwidths (6–23 Hz range), for the developed prototypes were determined. The maximal generated output power was almost 24 μW with a power density up to almost 600 μW/cm3.

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SURGICAL OUTCOMES OF 3D PRINTED MUSCULOSKELETAL METAL IMPLANTS: A SYSTEMATIC REVIEW

Journal of Musculoskeletal Research ◽

10.1142/s0218957718400018 ◽

2018 ◽

Vol 21 (03n04) ◽

pp. 1840001

Author(s):

C. Dion ◽

M. Pollock ◽

J. Howard ◽

L. Somerville ◽

B. Lanting

Keyword(s):

Systematic Review ◽

3D Printing ◽

Surgical Outcomes ◽

Maxillofacial Surgery ◽

Case Series ◽

Free Form ◽

Bibliographic Databases ◽

Surgical Practice ◽

Metal Implants ◽

3D Printed

Introduction: Additive manufacturing, also known as 3D printing (3DP), is becoming increasingly available to surgeons throughout the world due to recent advancements in technology. 3D printing can produce complex free-form structures that would be impossible using conventional subtractive manufacturing. This offers the possibility to create implants that are better suited to the irregular anatomic shapes found in the human body. The present study aims to examine the surgical outcomes associated with the use of 3D printed metal implants and uncover the value of 3D printing in musculoskeletal surgery. Methods: A systematic review of published literature was performed in June 2017 using the PRISMA protocol. Online bibliographic databases such as MEDLINE, Embase, Scopus, CINAHL, and Cochrane were used to identify studies involving surgical implantation of 3D printed metal implants in musculoskeletal surgery. References from relevant studies were scanned for additional articles. Two reviewers independently screened results. Full-text articles were analyzed for eligibility. A total of 24 studies were included for data abstraction. Results were collected and qualitatively analyzed. Results: Of the 25 articles included, there were 17 case reports, 4 case series, 2 retrospective cohorts and 3 prospective cohorts. Of these articles, the majority of 3DP was done with electron beam melting (EBM) with Ti6Al4V. Orthopaedic, neurosurgical, plastic, and maxillofacial surgery articles were included in the review. All studies concluded that 3D printed implants had favourable post-operative outcomes. Some advantages included the reduction of operative time, improved osseointegration through custom implant porosity, improved fixation, decreased stress shielding, better cosmetic appearance, improved functional outcome, and limb salvage. Additional cost and time required to design and print the implants were reported as potential drawbacks to 3D printing. Discussion/Conclusions. The applications of 3D printing in musculoskeletal surgery are promising and have the potential to alter future surgical practice. However, there is a lack of quality research in the literature assessing the use of 3D printed implants. Further research is needed to evaluate the use of 3D printing in musculoskeletal surgery to understand its potential effects on surgical practice.

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3D Printing of Polyamide to Fabricate a Non-Metal Clasp Removable Partial Denture via Fused Filament Fabrication: A Case Report

International Journal of Environmental Research and Public Health ◽

10.3390/ijerph18168241 ◽

2021 ◽

Vol 18 (16) ◽

pp. 8241

Author(s):

Sebastian Spintzyk ◽

Roman Schmunk ◽

Pablo Kraemer Fernandez ◽

Fabian Huettig ◽

Alexey Unkovskiy

Keyword(s):

Case Report ◽

Additive Manufacturing ◽

3D Printing ◽

Treatment Option ◽

Proof Of Concept ◽

Fused Filament Fabrication ◽

Removable Partial Denture ◽

Digital Workflow ◽

Partial Denture ◽

Temporary Treatment

The fabrication of a non-metal clasp removable partial denture (RPD) using polymethylmethacrylate in a fully digital workflow has been reported. According to some studies, the polyamide material may be alternatively used for this purpose. The authors are unaware of any reports concerning the additive manufacturing of polyamide. The current proof-of-concept dental technique describes the pathway to construct the non-metal clasp RPD using intraoral scanning and fused filament fabrication (FFF) printing of gingiva-colored polyamide. The present RPD showed acceptable fit and sufficient retention and was considered a valid temporary treatment option.

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3D Printed Snorkel Mask Adapter for Failed N95 Fit Tests and PPE Shortages

10.1101/2020.08.18.20174540 ◽

2020 ◽

Author(s):

Shiv Dalla ◽

Rohit Shinde ◽

Jack M Ayres ◽

Stephen Waller ◽

Jay Nachtigal

Keyword(s):

3D Printing ◽

Kansas City ◽

Protective Equipment ◽

Proof Of Concept ◽

University Of Kansas ◽

Fit Testing ◽

3D Printed ◽

Full Face ◽

The University ◽

N95 Respirators

Introduction The shortage of personal protective equipment (PPE) across the country has been widely discussed throughout the COVID-19 pandemic. Unfortunately, recent reports indicate that PPE shortages persist amidst continually increasing caseloads nationwide. Additionally, there have been reports of poor-fitting masks, a problem which is magnified by shortages. The lack of adequate access to conventional N95 masks pushed for some to pursue 3D printing and locally distributing their own manufactured masks as substitutes when PPE, including N95 masks, were not readily available. The design presented, the snorkel mask adapter, is one such design born from the local maker community in partnership with local physicians and hospitals. This article discusses the design, manufacturing, and validation of the snorkel mask adapter and its immediate use in the COVID-19 pandemic as well as future use as stopgap PPE. Methods The design presented is an adapter which can be used with a commercially available snorkel mask in order to serve as a full face respirator in either the case of a PPE shortage or more pertinently for those who are unable to pass fit testing with the available N95 respirators at their respective facilities. Mask components were 3D printed, assembled, and then fit tested by qualitative fit testing (QLFT) at The University of Kansas Health System (TUKHS) in Kansas City, KS as a proof of concept. Results At TUKHS, the mask was fit tested on 22 individuals who required an N95 mask but were not able to pass qualitative fit testing with the masks available to them at the time. Of the 22 tested, all 22 of them were able to pass QLFT with the snorkel mask, adapter, and viral/bacterial filter combination. Conclusion The results of the fit testing at TUKHS is promising for this N95 alternative. More extensive testing can and should be done, including quantitative fit testing. Persistently increasing caseloads and PPE shortages necessitates an urgent dissemination of these preliminary results. The authors do not advocate for this design as a replacement of traditional N95 masks or other PPE but do endorse this design as a stopgap measure, proven to be effective in situations of dire PPE shortage or for individuals who have failed fit testing with conventional PPE.

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Biodegradable 3D Printed Polymer Microneedles for Transdermal Drug Delivery

10.26434/chemrxiv.5851950.v1 ◽

2018 ◽

Cited By ~ 1

Author(s):

Michael A. Luzuriaga ◽

Danielle R. Berry ◽

John C. Reagan ◽

Ronald A. Smaldone ◽

Jeremiah J. Gassensmith

Keyword(s):

Drug Delivery ◽

3D Printing ◽

Transdermal Drug Delivery ◽

Fused Deposition Modeling ◽

Fused Deposition ◽

Modeling Software ◽

Deposition Modeling ◽

3D Printed ◽

Microfabrication Technique ◽

Mechanical Strengths

Biodegradable polymer microneedle (MN) arrays are an emerging class of transdermal drug delivery devices that promise a painless and sanitary alternative to syringes; however, prototyping bespoke needle architectures is expensive and requires production of new master templates. Here, we present a new microfabrication technique for MNs using fused deposition modeling (FDM) 3D printing using polylactic acid, an FDA approved, renewable, biodegradable, thermoplastic material. We show how this natural degradability can be exploited to overcome a key challenge of FDM 3D printing, in particular the low resolution of these printers. We improved the feature size of the printed parts significantly by developing a post fabrication chemical etching protocol, which allowed us to access tip sizes as small as 1 μm. With 3D modeling software, various MN shapes were designed and printed rapidly with custom needle density, length, and shape. Scanning electron microscopy confirmed that our method resulted in needle tip sizes in the range of 1 – 55 µm, which could successfully penetrate and break off into porcine skin. We have also shown that these MNs have comparable mechanical strengths to currently fabricated MNs and we further demonstrated how the swellability of PLA can be exploited to load small molecule drugs and how its degradability in skin can release those small molecules over time.

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