Validation of design and materials for additive manufacturing of endocavitary mechanical distractor

Purpose This paper describes the evolution of the design of a mechanical distractor fabricated using additive manufacturing (AM) technology for use in surgical procedures, such as transanal endoscopic microsurgery (TEM). The functionality of the final device was analysed and the suitability of different materials was determined. Design/methodology/approach Solid modelling and finite element modelling software were used in the design and validation process to allow the fabrication of the device by AM. Several prototypes were manufactured and tested in this study. Findings A new design was developed to greatly simplify the existing devices used in TEM surgery. The new design is easy to use, more economical and does not require pneumorectum. Different AM materials were investigated with regard to their mechanical properties, orientation of parts in the three-dimensional (3D) printer and cytotoxicity to select the optimal material for the design. Social implications The device designed by AM can be printed anywhere in the world, provided that a 3D printer is available; the 3D printer does not have to be a high-performance printer. This makes surgery more accessible, particularly in low-income regions. Moreover, patient recovery is improved and pneumorectum is not required. Originality/value A suitable mechanical distractor was designed for TEM, and different materials were validated for fabrication by AM.

The material ratio of roadside backfill body based on spatiotemporal law of ground pressure: a case study of Xingtai Mine, China

The material ratio of the roadside backfill body in gob-side entry retaining determines its mechanical properties, which plays an important role in the supporting effect of the roadway surrounding rock. In this paper, a similar material modeling is used to verify the spatiotemporal law of the ground pressure in the engineering case of dense solid backfilling mining in Xingtai Mine, China. Based on that law, the theoretical requirements for the bearing performance of the roadside backfill body are proposed. Finally, a material ratio that meets the theoretical requirements is obtained by compression test, and the deformation and failure characteristics of the backfill body with this ratio are analyzed. The results show that the maximum pressure of the backfill body measured in Xingtai Mine is 5.5 MPa, which is about 40 m away from the coal face, after 40m, the pressure of the backfill body will not increase anymore. The similar simulation test also proved that the ground pressure behind the coal face increases gradually and tends to be stable during the backfilling process, which shows certain spatiotemporal characteristics. Through the proportioning experiment, it is determined that the optimal material ratio of the roadside backfill body is gangue: fly ash: cement = 10:3:1, which meets the theoretical requirement that the strength of the roadside backfill body at any position is not less than the ground pressure at that position. The research results provide a reference for the engineering practice of gob-side entry retaining in dense backfilling mining.

CNC Milling of Medical-Grade PMMA

This study evaluates CNC milling parameters (spindle speed, depth of cut, and feed rate) on medical-grade PMMA. A single objective analysis conducted showed that the optimal material removal rate (MRR) occurs at a spindle speed of 1250 rpm, a depth of cut of 1.2 mm, and a feed rate of 350 mm/min. The ANOVA showed that feed rate is the most significant factor towards the MRR, and spindle speed (11.83%) is the least contributing. The optimal surface roughness (Ra) occurred at spindle speed of 500 rpm, depth of cut of 1.2 mm, and feed rate of 200 mm/min. The milling factors were insignificant. A regression analysis for prediction was also conducted. Further, a multi-objective optimization was conducted using the Grey Relational Analysis. It showed that the best trade-off between the MRR and the Ra could be obtained from a combination of 1250 rpm (spindle speed), 1.2 mm (depth of cut), and 350 mm/min (feed rate). The depth of cut was the largest contributor towards the grey relational grade (54.48%), followed by the feed rate (10.36%), and finally, the spindle speed (4.28%).

Rice Hull-Derived Carbon for Supercapacitors: Towards Sustainable Silicon-Carbon Supercapacitors

A simple and effective mixing carbonization-activation process was developed to prepare rice hull-derived porous Si–carbon materials. The morphologies and pore structures of the materials were controlled effectively without any loading or additions at various carbonization temperatures. The structures of the samples changed from large pores and thick walls after 800 ∘C carbonization to small pores and thin walls after 1000 ∘C carbonization. An additional alkali activation–carbonization process led to coral reef-like structures surrounded by squama in the sample that underwent 900 ∘C carbonization (Act-RH-900). This optimal material (Act-RH-900) had a large specific surface area (768 m2 g−1), relatively stable specific capacitance (150.8 F g−1), high energy density (31.9 Wh kg−1), and high-power density (309.2 w kg−1) at a current density of 0.5 A g−1 in 1 M KOH electrolyte, as well as a good rate performance and high stability (capacitance retention > 87.88% after 5000 cycles). The results indicated that Act-RH-900 is a promising candidate for capacitive applications. This work overcomes the restrictions imposed by the complex internal structure of biomass, implements a simple reaction environment, and broadens the potential applicability of biomass waste in the field of supercapacitors.

Surface Characterization and Anti-Biofilm Effectiveness of Hybrid Films of Polyurethane Functionalized with Saponite and Phloxine B

The main objective of this work was to synthesize composites of polyurethane (PU) with organoclays (OC) exhibiting antimicrobial properties. Layered silicate (saponite) was modified with octadecyltrimethylammonium cations (ODTMA) and functionalized with phloxine B (PhB) and used as a filler in the composites. A unique property of composite materials is the increased concentration of modifier particles on the surface of the composite membranes. Materials of different compositions were tested and investigated using physico-chemical methods, such as infrared spectroscopy, X-ray diffraction, contact angle measurements, absorption, and fluorescence spectroscopy in the visible region. The composition of an optimal material was as follows: nODTMA/mSap = 0.8 mmol g−1 and nPhB/mSap = 0.1 mmol g−1. Only about 1.5% of present PhB was released in a cultivation medium for bacteria within 24 h, which proved good stability of the composite. Anti-biofilm properties of the composite membranes were proven in experiments with resistant Staphylococcus aureus. The composites without PhB reduced the biofilm growth 100-fold compared to the control sample (non-modified PU). The composite containing PhB in combination with the photodynamic inactivation (PDI) reduced cell growth by about 10,000-fold, thus proving the significant photosensitizing effect of the membranes. Cell damage was confirmed by scanning electron microscopy. A new method of the synthesis of composite materials presented in this work opens up new possibilities for targeted modification of polymers by focusing on their surfaces. Such composite materials retain the properties of the unmodified polymer inside the matrix and only the surface of the material is changed. Although these unique materials presented in this work are based on PU, the method of surface modification can also be applied to other polymers. Such modified polymers could be useful for various applications in which special surface properties are required, for example, for materials used in medical practice.

Increasing the durability of the coupling "crankshaft neck – bearing liner" by applying nanocomposite additives to the engine oils of marine medium-speed diesel engines

Повышение долговечности трибосопряжений судовых дизелей, определяющих их ресурс, представляет собой актуальнейшую проблему, обусловленную как безопасностью мореплавания, так и экономическими факторами. Основной причиной отказов коленчатых валов двигателей, определяющих необходимость капитального ремонта, является износ шеек. Решение проблемы повышения износостойкости и, соответственно, долговечности связано с применением трибоактивных присадок в смазку. Несмотря на глубокие и обстоятельные исследования в области применения органо-неорганических материалов для использования в качестве присадок в моторное масло для повышения долговечности трибоузлов осуществить выбор оптимального материала для конкретных условий практически невозможно, так как исследования выполнены для различных условий эксплуатации и по различным методикам. Цель работы – разработка триботехнической присадки к моторным маслам, обеспечивающей повышение надежности и эффективности технической эксплуатации судовыхсреднеоборотных дизелей путем формирования тонкопленочного металлокерамического покрытия на поверхностях трения стальных деталей трибоузлов, позволяющего получить оптимальный комплекс параметров материала износостойкого покрытия. В работе представлены исследования эксплуатационных свойств присадок в моторное масло 17 органо-неорганических триботехнических материалов 4 групп — природные и искусственные полимеры, из которых были изготовлены свыше 20 композиций и композитов. Установлено, что наиболее перспективным является использование нанокомпозитов на основе вермикулита, модифицированного кислотой, в качестве присадок в моторное масло, так как они обладают минимальными коэффициентом трения при граничной смазке (0,007–0,014) а также высокой износостойкостью стали 40Х и обеспечивают минимальную величину скорости изнашивания вкладыша подшипника, благодаря чему повышается ресурс трибосопряжения более, чем в 3 раза, и соответственно снижаются эксплуатационные расходы. Increasing the durability of the tribo-couplings of marine diesel engines, which determine their resource, is an urgent problem due to both the safety of navigation and economic factors. The main reason for engine crankshafts failures, which determine the need for major repairs, is the wear of the necks. The solution to the problem of increasing wear resistance and, accordingly, durability is associated with the use of triboactive additives in the lubricant. Despite in-depth and thorough research in the field of application of organo-inorganic materials for use as additives in engine oil to increase the durability of tribo-nodes, it is almost impossible to choose the optimal material for specific conditions, since the studies were carried out for various operating conditions and according to various methods. The purpose of the work is to develop a tribotechnical additive to motor oils that provides an increase in the reliability and efficiency of technical operation of medium-speed marine diesel engines by forming a thin-film metal-ceramic coating on the friction surfaces of steel parts of tribo-nodes, which allows to obtain an optimal set of parameters of the wear-resistant coating material. The paper presents studies of the operational properties of additives in engine oil of 17 organo-inorganic tribotechnical materials of 4 groups — natural and artificial polymers, from which more than 20 compositions and composites were made. It has been established that the most promising is the use of nanocomposites based on vermiculite modified with acid as additives in engine oil, since they have a minimum coefficient of friction with boundary lubrication (0.007-0.014) as well as high wear resistance of 40X steel and provide a minimum wear rate of the bearing liner, thereby increasing the tribo-tension life by more than 3 times, and, accordingly, operating costs are reduced.

A pessimistic bilevel stochastic problem for elastic shape optimization

We consider pessimistic bilevel stochastic programs in which the follower maximizes over a fixed compact convex set a strictly convex quadratic function, whose Hessian depends on the leader’s decision. This results in a random upper level outcome which is evaluated by a convex risk measure. Under assumptions including real analyticity of the lower-level goal function, we prove the existence of optimal solutions. We discuss an alternate model, where the leader hedges against optimal lower-level solutions, and show that solvability can be guaranteed under weaker conditions in both, a deterministic and a stochastic setting. The approach is applied to a mechanical shape optimization problem in which the leader decides on an optimal material distribution to minimize a tracking-type cost functional, whereas the follower chooses forces from an admissible set to maximize a compliance objective. The material distribution is considered to be stochastically perturbed in the actual construction phase. Computational results illustrate the bilevel optimization concept and demonstrate the interplay of follower and leader in shape design and testing.

Numerical and Experimental Stress-Strain Analysis of a Rubber Carousel

The effect of the impact load exerted by the baggage impacting light baggage carousels may be manifested as mechanical damage to the carousel as a result of the stress-strain processes. In order to describe the phenomena related to the baggage impact, it is important to monitor the tensile strength of rubber carousels of light conveyor belts intended for the conveyance of baggage at airports. The output of the article is monitoring the mechanical load of the carousel, the comparison of the results thereof with the outputs of the CAE analysis, as well as the determination of the optimal material model and the approximation thereof to the experimental model.

Volumetric Tomographic 3D Bioprinting of Heterocellular Bone-like Tissues in Seconds

3D bioprinting has emerged as a powerful tool for custom fabrication of biomimetic hydrogel constructs that support the differentiation of stem cells into functional bone tissues. Existing stem cell-derived in vitro bone models, however, often lack terminally differentiated bone cells named osteocytes which are crucial for bone homeostasis. Here, we report ultrafast volumetric tomographic photofabrication of centimeter-scale heterocellular bone models that enabled successful 3D osteocytic differentiation of human mesenchymal stem cells (hMSCs) within hydrogels after 42 days co-culture with human umbilical vein endothelial cell (HUVECs). It is hypothesized that after 3D bioprinting the paracrine signaling between hMSCs and HUVECs will promote their differentiation into osteocytes while recreating the complex heterocellular bone microenvironment. To this, we formulated a series of bioinks with varying concentrations of gelatin methacryloyl (GelMA) and lithium Phenyl(2,4,6-trimethylbenzoyl)phosphinate (LAP). A bioink comprising 5% GelMA and 0.05% LAP was identified as an optimal material with high cell viability (>90%) and excellent structural fidelity. Increasing LAP concentration led to much lower degree of cell spreading, presumably due to phototoxicity effects. Biochemical assays evidenced significantly increased expression of both osteoblastic markers (collagen-I, ALP, osteocalcin) and osteocytic markers (Podoplanin, PDPN; dentin matrix acidic phosphoprotein 1, Dmp1) after 3D co-cultures for 42 days. Additionally, we demonstrate volumetric 3D bioprinting of perfusable, pre-vascularized bone models where HUVECs self-organized into an endothelium-lined channel within 2 days. Altogether, this work leverages the benefits of volumetric tomographic bioprinting and 3D co-culture, offering a promising platform for scaled biofabrication of 3D bone-like tissues with unprecedented long-term functionality.