2D PCB WITH 3D PRINT FABRICATIONS FOR RIGID-CONFORMAL PACKAGING OF MICROSENSOR IMAGING ARRAYS BASED ON BIOINSPIRED ARCHITECTURES

2014 ◽  
Vol 2014 (DPC) ◽  
pp. 001012-001045
Author(s):  
David Fries ◽  
Chase StarrGeran Barton
Keyword(s):  
3D Printing ◽  
Sensor Systems ◽  
Construction Process ◽  
Imaging Arrays ◽  
Fused Deposition ◽  
Printed Circuits ◽  
Camera Systems ◽  
Macro Scale ◽  
3D Printed ◽  
Single Sensor

Macro sensor systems typically measure a localized space above a single sensor element. Expanding these single sensor elements into arrays permits spatial distribution measurements of a particular parameter and allow flux visualizations. Furthermore, applying microsystems technology to macro sensor systems yields imaging arrays and high resolution spatial/temporal sensing functions. Extending the high spatial resolution imaging over large areas is a desirable feature for new “vision” modes on autonomous robotic systems and for deployable environmental sensors. Rigid-flexible PCB's are desirable for miniaturization and integration of systems for mobile technology. The hybrid substrates provide substantial flexibility in systems design and integration of multiple functions into limited spaces. Using this design and construction approach allows lightweight, complex, and space efficient systems. Flex microsystems based on structured, fiber or non-fiber filled PCB laminates permits packaging to occur at two levels, at the local (micro) substrate scale and at the macro scale with the ability to flex the system across millimeter to centimeter lengths on real everyday systems. We continue to explore the use of PCB and PCBMEMS technology for new sensing concepts. In order to create rigid-conformal, large area imaging “camera” systems we have merged flexible PCB substrates with rigid constructions from 3D printing. This approach merges the 2D flexible electronics world of printed circuits with the 3D printed packaging world. Furthermore employing architectures used by biology as a basis for our imaging systems we explored naturally and biologically inspired designs, and their relationships to non-visible imagery, and alternate mechanical systems of perception. Radiolaria are extremely tiny ocean organisms that utilize a similar additive construction process to 3D printing. Their cell bodies secrete a substance mainly composed of silica to form intricate exoskeletons used as a system of protection. A correlation can be made between the radiolaria's construction process and the plastic extrusion system of the 3D fused deposition model printer. The benefits of additive construction are efficient use of materials, reduced cost and energy, and ability to customize forms. Through the use of bio-inspiration, a framework is laid out to base further research on (DFP)-design for packaging. Radiolarian exoskeletons take on a grid-like pattern while creating a cage around each microsensor interior and producing strong scaffolding. Using the 3D printed exoskeleton's form and function with flexible printed circuits one can create systems that are both rigid and form fitting with three-dimensional shape and enable new camera systems for various sensory applications.

Ocean Sensor “Imaging” Arrays Based on Bio-inspired Architectures and 2-D/3-D Construction

2015 ◽  
Vol 49 (3) ◽  
pp. 43-49 ◽  
Author(s):  
David P. Fries ◽  
Chase A. Starr ◽  
Geran W. Barton
Keyword(s):  
Flexible Electronics ◽  
Printed Circuit Board ◽  
Single Point ◽  
Circuit Board ◽  
Sensor Systems ◽  
Large Area ◽  
Imaging Arrays ◽  
Printed Circuits ◽  
Single Sensor ◽  
New Vision

AbstractMany common ocean sensor systems measure a localized space above a single sensor element. Single-point measurements give magnitude but not necessarily direction information. Expanding single sensor elements, such as used in salinity sensors, into arrays permits spatial distribution measurements and allows flux visualizations. Furthermore, applying microsystem technology to these macro sensor systems can yield imaging arrays with high-resolution spatial/temporal sensing functions. Extending such high spatial resolution imaging over large areas is a desirable feature for new “vision” modes on autonomous robotic systems and for deployable ocean sensor systems. The work described here explores the use of printed circuit board (PCB) technology for new sensing concepts and designs. In order to create rigid-conformal, large area imaging “camera” systems, we have merged flexible PCB substrates with rigid constructions from 3-D printing. This approach merges the 2-D flexible electronics world of printed circuits with the 3-D printed packaging world. Furthermore, employing architectures used by biology as a basis for our imaging systems, we explored naturally and biologically inspired designs, their relationships to visual imagining, and alternate mechanical systems of perception. Through the use of bio-inspiration, a framework is laid out to base further research on design for packaging of ocean sensors and arrays. Using 3-D printed exoskeleton's rigid form with flexible printed circuits, one can create systems that are both rigid and form-fitting with 3-D shape and enable new sensor systems for various ocean sensory applications.

Biodegradable 3D Printed Polymer Microneedles for Transdermal Drug Delivery

2018 ◽  
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.

scholarly journals Design of a 3D-printed hand prosthesis featuring articulated bio-inspired fingers

2020 ◽  
pp. 095441192098088
Author(s):  
Juan Sebastian Cuellar ◽  
Dick Plettenburg ◽  
Amir A Zadpoor ◽  
Paul Breedveld ◽  
Gerwin Smit
Keyword(s):  
3D Printing ◽  
Design Principles ◽  
Prosthetic Hand ◽  
Hand Prosthesis ◽  
Fused Deposition ◽  
Pinch Force ◽  
Actuation System ◽  
3D Printed ◽  
Energy Dissipated ◽  
Dual Material

Various upper-limb prostheses have been designed for 3D printing but only a few of them are based on bio-inspired design principles and many anatomical details are not typically incorporated even though 3D printing offers advantages that facilitate the application of such design principles. We therefore aimed to apply a bio-inspired approach to the design and fabrication of articulated fingers for a new type of 3D printed hand prosthesis that is body-powered and complies with basic user requirements. We first studied the biological structure of human fingers and their movement control mechanisms in order to devise the transmission and actuation system. A number of working principles were established and various simplifications were made to fabricate the hand prosthesis using a fused deposition modelling (FDM) 3D printer with dual material extrusion. We then evaluated the mechanical performance of the prosthetic device by measuring its ability to exert pinch forces and the energy dissipated during each operational cycle. We fabricated our prototypes using three polymeric materials including PLA, TPU, and Nylon. The total weight of the prosthesis was 92 g with a total material cost of 12 US dollars. The energy dissipated during each cycle was 0.380 Nm with a pinch force of ≈16 N corresponding to an input force of 100 N. The hand is actuated by a conventional pulling cable used in BP prostheses. It is connected to a shoulder strap at one end and to the coupling of the whiffle tree mechanism at the other end. The whiffle tree mechanism distributes the force to the four tendons, which bend all fingers simultaneously when pulled. The design described in this manuscript demonstrates several bio-inspired design features and is capable of performing different grasping patterns due to the adaptive grasping provided by the articulated fingers. The pinch force obtained is superior to other fully 3D printed body-powered hand prostheses, but still below that of conventional body powered hand prostheses. We present a 3D printed bio-inspired prosthetic hand that is body-powered and includes all of the following characteristics: adaptive grasping, articulated fingers, and minimized post-printing assembly. Additionally, the low cost and low weight make this prosthetic hand a worthy option mainly in locations where state-of-the-art prosthetic workshops are absent.

scholarly journals Mechanical Characterization and Thermodynamic Analysis of Laser-Polished Landscape Design Products Using 3D Printing

Materials ◽  
2021 ◽  
Vol 14 (10) ◽  
pp. 2601
Author(s):  
Yue Ba ◽  
Yu Wen ◽  
Shibin Wu
Keyword(s):  
Surface Roughness ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
High Surface ◽  
Landscape Design ◽  
Laser Polishing ◽  
Fused Deposition ◽  
Design Structure ◽  
3D Printed ◽  
Stability And Accuracy

Recent innovations in 3D printing technologies and processes have influenced how landscape products are designed, built, and developed. In landscape architecture, reduced-size models are 3D-printed to replicate full-size structures. However, high surface roughness usually occurs on the surfaces of such 3D-printed components, which requires additional post-treatment. In this work, we develop a new type of landscape design structure based on the fused deposition modeling (FDM) technique and present a laser polishing method for FDM-fabricated polylactic acid (PLA) mechanical components, whereby the surface roughness of the laser-polished surfaces is reduced from over Ra 15 µm to less than 0.25 µm. The detailed results of thermodynamics and microstructure evolution are further analyzed during laser polishing. The stability and accuracy of the results are evaluated based on the standard deviation. Additionally, the superior tensile and flexural properties are examined in the laser-polished layer, in which the ultimate tensile strength (UTS) is increased by up to 46.6% and the flexural strength is increased by up to 74.5% compared with the as-fabricated components. Finally, a real polished landscape model is simulated and optimized using a series of scales.

scholarly journals 3D Printed Clamps for In Vitro Tensile Tests of Human Gracilis and the Superficial Third of Quadriceps Tendons

2021 ◽  
Vol 11 (6) ◽  
pp. 2563
Author(s):  
Ivan Grgić ◽  
Vjekoslav Wertheimer ◽  
Mirko Karakašić ◽  
Željko Ivandić
Keyword(s):  
3D Printing ◽  
Fused Deposition Modeling ◽  
Tensile Tests ◽  
Biomechanical Properties ◽  
Testing Procedure ◽  
Laboratory Equipment ◽  
Fused Deposition ◽  
Custom Made ◽  
3D Printed

Recent soft tissue studies have reported issues that occur during experimentation, such as the tissue slipping and rupturing during tensile loads, the lack of standard testing procedure and equipment, the necessity for existing laboratory equipment adaptation, etc. To overcome such issues and fulfil the need for the determination of the biomechanical properties of the human gracilis and the superficial third of the quadriceps tendons, 3D printed clamps with metric thread profile-based geometry were developed. The clamps’ geometry consists of a truncated pyramid pattern, which prevents the tendons from slipping and rupturing. The use of the thread application in the design of the clamp could be used in standard clamping development procedures, unlike in previously custom-made clamps. Fused deposition modeling (FDM) was used as a 3D printing technique, together with polylactic acid (PLA), which was used as a material for clamp printing. The design was confirmed and the experiments were conducted by using porcine and human tendons. The findings justify the usage of 3D printing technology for parts manufacturing in the case of tissue testing and establish independence from the existing machine clamp system, since it was possible to print clamps for each prepared specimen and thus reduce the time for experiment setup.

scholarly journals 3D Printing of Thermo-Sensitive Drugs

Pharmaceutics ◽  
2021 ◽  
Vol 13 (9) ◽  
pp. 1524
Author(s):  
Sadikalmahdi Abdella ◽  
Souha H. Youssef ◽  
Franklin Afinjuomo ◽  
Yunmei Song ◽  
Paris Fouladian ◽  
...  
Keyword(s):  
3D Printing ◽  
Three Dimensional ◽  
Fused Deposition Modelling ◽  
Future Directions ◽  
Digital Light Processing ◽  
Fused Deposition ◽  
Printing Technique ◽  
3D Printed ◽  
Semi Solid ◽  
Selection Of

Three-dimensional (3D) printing is among the rapidly evolving technologies with applications in many sectors. The pharmaceutical industry is no exception, and the approval of the first 3D-printed tablet (Spiratam®) marked a revolution in the field. Several studies reported the fabrication of different dosage forms using a range of 3D printing techniques. Thermosensitive drugs compose a considerable segment of available medications in the market requiring strict temperature control during processing to ensure their efficacy and safety. Heating involved in some of the 3D printing technologies raises concerns regarding the feasibility of the techniques for printing thermolabile drugs. Studies reported that semi-solid extrusion (SSE) is the commonly used printing technique to fabricate thermosensitive drugs. Digital light processing (DLP), binder jetting (BJ), and stereolithography (SLA) can also be used for the fabrication of thermosensitive drugs as they do not involve heating elements. Nonetheless, degradation of some drugs by light source used in the techniques was reported. Interestingly, fused deposition modelling (FDM) coupled with filling techniques offered protection against thermal degradation. Concepts such as selection of low melting point polymers, adjustment of printing parameters, and coupling of more than one printing technique were exploited in printing thermosensitive drugs. This systematic review presents challenges, 3DP procedures, and future directions of 3D printing of thermo-sensitive formulations.

On 3D printing of electro-active PVDF-Graphene and Mn-doped ZnO nanoparticle-based composite as a self-healing repair solution for heritage structures

2021 ◽  
pp. 095440542110609
Author(s):  
Vinay Kumar ◽  
Rupinder Singh ◽  
Inderpreet Singh Ahuja
Keyword(s):  
3D Printing ◽  
Polyvinylidene Fluoride ◽  
Nano Particles ◽  
Zno Nanoparticle ◽  
Self Healing ◽  
Fused Deposition ◽  
Crack Repair ◽  
3D Printed ◽  
Doped Zno ◽  
Mn Doped

Construction is the part of human activity which is directly linked to urbanization for moving ahead on the path of growth and prosperity. Construction activities in past centuries are now part of our precious heritage. The repair and maintenance of heritage structures are of great importance for present-day researchers. One of the most common damage these century-long constructions faces are in form of surface cracks. In the present study, investigations were performed for a 3D printing-based customized solution for crack repair and maintenance of heritage structures. In this study, polyvinylidene fluoride (PVDF) polymer was reinforced with graphene (Gr) and Mn-doped ZnO nano-particles to prepare a smart composite material for crack repair and restoration. The composite was successfully 3D printed on fused deposition modeling (FDM) based 3D printer after investigating its rheological, thermal, and mechanical properties. The in-house developed composite was tested for smart characteristics to use as a programmable solution for filling cracks. The piezoelectric property and dielectric constant of 3D printed disk-shaped composite (PVDF-Gr-Mn-ZnO) were obtained after DC poling (to be used as stimulus) of the functional prototype. The results of the study suggest that the electro-active nature, volumetric change, and charge storing capacity of the additively manufactured composite may be used practically to acquire the shape of cavity/crack present in the constructed wall and repair the damages that occurred in a heritage site. The photoluminescence (PLS) and atomic force microscopy (AFM) analysis was used to ascertain the properties of the prepared composite. Also, the results obtained from the morphological analysis are reported to support the outcomes of the research.

Use of polymer concrete for large-scale 3D printing

2021 ◽  
Vol 27 (3) ◽  
pp. 465-474
Author(s):  
Martin Krčma ◽  
David Škaroupka ◽  
Petr Vosynek ◽  
Tomáš Zikmund ◽  
Jozef Kaiser ◽  
...  
Keyword(s):  
3D Printing ◽  
Large Scale ◽  
Mechanical Performance ◽  
Construction Material ◽  
Polymer Concrete ◽  
Fused Deposition Modelling ◽  
Cast State ◽  
Content Type ◽  
Fused Deposition ◽  
3D Printed

Purpose This paper aims to focus on the evaluation of a polymer concrete as a three-dimensional (3D) printing material. An associated company has developed plastic concrete made from reused unrecyclable plastic waste. Its intended use is as a construction material. Design/methodology/approach The concrete mix, called PolyBet, composed of polypropylene and glass sand, is printed by the fused deposition modelling process. The process of material and parameter selection is described. The mechanical properties of the filled material were compared to its cast state. Samples were made from castings and two different orientations of 3D-printed parts. Three-point flex tests were carried out, and the area of the break was examined. Computed tomography of the samples was carried out. Findings The influence of the 3D printing process on the material was evaluated. The mechanical performance of the longitudinal samples was close to the cast state. There was a difference in the failure mode between the states, with cast parts exhibiting a tougher behaviour, with fractures propagating in a stair-like manner. The 3D-printed samples exhibited high degrees of porosity. Originality/value The results suggest that the novel material is a good fit for 3D printing, with little to no degradation caused by the process. Layer adhesion was shown to be excellent, with negligible effect on the finished part for the longitudinal orientation. That means, if large-scale testing of buildability is successful, the material is a good fit for additive manufacturing of building components and other large-scale structures.

Flexible Strain Sensor Using Additive Manufacturing and Conductive Liquid Metal: Design, Fabrication, and Characterization

2018 ◽  
Author(s):  
Austin Smith ◽  
Hamzeh Bardaweel
Keyword(s):  
3D Printing ◽  
Liquid Metal ◽  
Strain Sensor ◽  
Gauge Factor ◽  
Limiting Factor ◽  
Successful Implementation ◽  
Conductive Liquid ◽  
Fused Deposition ◽  
3D Printed ◽  
Flexible Strain Sensor

In this work a flexible strain sensor is fabricated using Fused Deposition Modeling (FDM) 3D printing technique. The strain sensor is fabricated using commercially available flexible Thermoplastic Polyurethane (TPU) filaments and liquid metal Galinstan Ga 68.5% In 21% Sn 10%. The strain sensor consists of U-shape 2.34mm long and 0.2mm deep channels embedded inside a TPU 3D printed structure. The performance of the strain sensor is measured experimentally. Gauge Factor is estimated by measuring change in electric resistance when the sensor is subject to 13.2% – 38.6% strain. Upon straining and unstraining, results from characterization tests show high linearity in the range of 13.2% to 38.6% strain with very little hysteresis. However, changes due to permanent deformations are a limiting factor in the usefulness of these sensors because these changes limit the consistency of the device. FDM 3D printing shows promise as a method for fabricating flexible strain sensors. However, more investigation is needed to look at the effects of geometries and 3D printing process parameters on the yield elongation of the flexible filaments. Additionally, more investigation is needed to observe the effect of distorted dimensions of the 3D printed channels on the sensitivity of the strain sensor. It is anticipated that successful implementation of these commercially available filaments and FDM 3D printers will lead to reduction in cost and complexity of developing these flexible sensors.

scholarly journals 3D-Printable PP/SEBS Thermoplastic Elastomeric Blends: Preparation and Properties

Polymers ◽  
2019 ◽  
Vol 11 (2) ◽  
pp. 347 ◽  
Author(s):  
Shib Banerjee ◽  
Stephen Burbine ◽  
Nischay Kodihalli Shivaprakash ◽  
Joey Mead
Keyword(s):  
3D Printing ◽  
Carbon Black ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Polymeric Materials ◽  
Fused Deposition ◽  
3D Printed ◽  
Injection Molded ◽  
Preferential Location

Currently, material extrusion 3D printing (ME3DP) based on fused deposition modeling (FDM) is considered a highly adaptable and efficient additive manufacturing technique to develop components with complex geometries using computer-aided design. While the 3D printing process for a number of thermoplastic materials using FDM technology has been well demonstrated, there still exists a significant challenge to develop new polymeric materials compatible with ME3DP. The present work reports the development of ME3DP compatible thermoplastic elastomeric (TPE) materials from polypropylene (PP) and styrene-(ethylene-butylene)-styrene (SEBS) block copolymers using a straightforward blending approach, which enables the creation of tailorable materials. Properties of the 3D printed TPEs were compared with traditional injection molded samples. The tensile strength and Young’s modulus of the 3D printed sample were lower than the injection molded samples. However, no significant differences could be found in the melt rheological properties at higher frequency ranges or in the dynamic mechanical behavior. The phase morphologies of the 3D printed and injection molded TPEs were correlated with their respective properties. Reinforcing carbon black was used to increase the mechanical performance of the 3D printed TPE, and the balancing of thermoplastic elastomeric and mechanical properties were achieved at a lower carbon black loading. The preferential location of carbon black in the blend phases was theoretically predicted from wetting parameters. This study was made in order to get an insight to the relationship between morphology and properties of the ME3DP compatible PP/SEBS blends.

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