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- ItemBiocompatible Micron-Scale Silk Fibers Fabricated by Microfluidic Wet Spinning(Weinheim : Wiley-VCH, 2021) Lüken, Arne; Geiger, Matthias; Steinbeck, Lea; Joel, Anna-Christin; Lampert, Angelika; Linkhorst, John; Wessling, MatthiasFor successful material deployment in tissue engineering, the material itself, its mechanical properties, and the microscopic geometry of the product are of particular interest. While silk is a widely applied protein-based tissue engineering material with strong mechanical properties, the size and shape of artificially spun silk fibers are limited by existing processes. This study adjusts a microfluidic spinneret to manufacture micron-sized wet-spun fibers with three different materials enabling diverse geometries for tissue engineering applications. The spinneret is direct laser written (DLW) inside a microfluidic polydimethylsiloxane (PDMS) chip using two-photon lithography, applying a novel surface treatment that enables a tight print-channel sealing. Alginate, polyacrylonitrile, and silk fibers with diameters down to 1 µm are spun, while the spinneret geometry controls the shape of the silk fiber, and the spinning process tailors the mechanical property. Cell-cultivation experiments affirm bio-compatibility and showcase an interplay between the cell-sized fibers and cells. The presented spinning process pushes the boundaries of fiber fabrication toward smaller diameters and more complex shapes with increased surface-to-volume ratio and will substantially contribute to future tailored tissue engineering materials for healthcare applications. © 2021 The Authors. Advanced Healthcare Materials published by Wiley-VCH GmbH
- ItemViscous Flow of Supercooled Liquid in a Zr-Based Bulk Metallic Glass Synthesized by Additive Manufacturing(Basel : MDPI, 2020) Kosiba, Konrad; Deng, Liang; Scudino, SergioThe constraint in sample size imposed by the critical cooling rate necessary for glass formation using conventional casting techniques is possibly the most critical limitation for the extensive use of bulk metallic glasses (BMGs) in structural applications. This drawback has been recently overcome by processing glass-forming systems via additive manufacturing, finally enabling the synthesis of BMGs with no size limitation. Although processing by additive manufacturing allows fabricating BMG objects with virtually no shape limitation, thermoplastic forming of additively manufactured BMGs may be necessary for materials optimization. Thermoplastic forming of BMGs is carried out above the glass transition temperature, where these materials behave as highly viscous liquids; the analysis of the viscosity is thus of primary importance. In this work, the temperature dependence of viscosity of the Zr52.5Cu17.9Ni14.6Al10Ti5 metallic glass fabricated by casting and laser powder bed fusion (LPBF) is investigated. We observed minor differences in the viscous flow of the specimens fabricated by the different techniques that can be ascribed to the higher porosity of the LPBF metallic glass. Nevertheless, the present results reveal a similar overall variation of viscosity in the cast and LPBF materials, which offers the opportunity to shape additively manufactured BMGs using already developed thermoplastic forming techniques.
- ItemApproach to Estimate the Phase Formation and the Mechanical Properties of Alloys Processed by Laser Powder Bed Fusion via Casting(Basel : MDPI, 2022) Kühn, Uta; Sander, Jan; Gabrysiak, Katharina Nicole; Giebeler, Lars; Kosiba, Konrad; Pilz, Stefan; Neufeld, Kai; Boehm, Anne Veronika; Hufenbach, Julia KristinA high-performance tool steel with the nominal composition Fe85Cr4Mo8V2C1 (wt%) was processed by three different manufacturing techniques with rising cooling rates: conventional gravity casting, centrifugal casting and an additive manufacturing process, using laser powder bed fusion (LPBF). The resulting material of all processing routes reveals a microstructure, which is composed of martensite, austenite and carbides. However, comparing the size, the morphology and the weight fraction of the present phases, a significant difference of the gravity cast samples is evident, whereas the centrifugal cast material and the LPBF samples show certain commonalities leading finally to similar mechanical properties. This provides the opportunity to roughly estimate the mechanical properties of the material fabricated by LPBF. The major benefit arises from the required small material quantity and the low resources for the preparation of samples by centrifugal casting in comparison to the additive manufacturing process. Concluding, the present findings demonstrate the high attractiveness of centrifugal casting for the effective material screening and hence development of novel alloys adapted to LPBF-processing.
- ItemPhase formation, thermal stability and mechanical properties of a Cu-Al-Ni-Mn shape memory alloy prepared by selective laser melting(São Carlos : Universidade Federal de São Carlos, 2015) Gargarella, Piter; Kiminami, Cláudio Shyinti; Mazzer, Eric Marchezini; Cava, Régis Daniel; Basilio, Leonardo Albuquerque; Bolfarini, Claudemiro; Botta, Walter José; Eckert, Jürgen; Gustmann, Tobias; Pauly, SimonSelective laser melting (SLM) is an additive manufacturing process used to produce parts with complex geometries layer by layer. This rapid solidification method allows fabricating samples in a non-equilibrium state and with refined microstructure. In this work, this method is used to fabricate 3 mm diameter rods of a Cu-based shape memory alloy. The phase formation, thermal stability and mechanical properties were investigated and correlated. Samples with a relative density higher than 92% and without cracks were obtained. A single monoclinic martensitic phase was formed with average grain size ranging between 28 to 36 μm. The samples exhibit a reverse martensitic transformation temperature around 106 ± 2 °C and a large plasticity in compression (around 15±1%) with a typical “double-yielding” behaviour.
- ItemHelixJet: An innovative plasma source for next-generation additive manufacturing (3D printing)(Hoboken, NJ : Wiley Interscience, 2020) Schäfer, Jan; Quade, Antje; Abrams, Kerry J.; Sigeneger, Florian; Becker, Markus M.; Majewski, Candice; Rodenburg, CorneliaA novel plasma source (HelixJet) for use in additive manufacturing (AM)/3D printing is proposed. The HelixJet is a capacitively coupled radio frequency plasma with a double-helix electrode configuration that generates a surprisingly stable and homogeneous glow plasma at low flow rates of argon and its mixtures at atmospheric pressure. The HelixJet was tested on three polyamide powders usually used to produce parts by laser sintering, a powder-based AM process, to form local deposits. The chemical composition of such plasma-printed samples is compared with thermally produced and laser-sintered samples with respect to differences in morphology that result from the different thermal cycles on several length scales. Plasma prints exhibit unique features attributable to the nonequilibrium chemistry and to the high-speed heat exchange.
- ItemLaser Powder Bed Fusion Processing of Fe-Mn-Al-Ni Shape Memory Alloy - On the Effect of Elevated Platform Temperatures(Basel : MDPI, 2021) Ewald, Felix Clemens; Brenne, Florian; Gustmann, Tobias; Vollmer, Malte; Krooß, Philipp; Niendorf, ThomasIn order to overcome constraints related to crack formation during additive processing (laser powder bed fusion, L-BPF) of Fe-Mn-Al-Ni, the potential of high-temperature L-PBF processing was investigated in the present study. The effect of the process parameters on crack formation, grain structure, and phase distribution in the as-built condition, as well as in the course of cyclic heat treatment was examined by microstructural analysis. Optimized processing parameters were applied to fabricate cylindrical samples featuring a crack-free and columnar grained microstructure. In the course of cyclic heat treatment, abnormal grain growth (AGG) sets in, eventually promoting the evolution of a bamboo like microstructure. Testing under tensile load revealed a well-defined stress plateau and reversible strains of up to 4%.
- ItemSelective laser melting of Ti-45Nb alloy(Basel : MDPI, 2015) Schwab, Holger; Prashanth, Konda Gokuldoss; Löber, Lukas; Kühn, Uta; Eckert, JürgenTi-45Nb is one of the potential alloys that can be applied for biomedical applications as implants due to its low Young’s modulus. Ti-45Nb (wt.%) gas atomized powders were used to produce bulk samples by selective laser melting with three different parameter sets (energy inputs). A β-phase microstructure consisting of elliptical grains with an enriched edge of titanium was observed by scanning electron microscopy and X-ray diffraction studies. The mechanical properties of these samples were evaluated using hardness and compression tests, which suggested that the strength of the samples increases with increasing energy input within the range considered.
- ItemPorous PVDF Monoliths with Templated Geometry(Weinheim : Wiley, 2021) Djeljadini, Suzana; Bongartz, Patrick; Alders, Michael; Hartmann, Nils; Oing, Alexander; Cornelissen, Christian; Hesselmann, Felix; Arens, Jutta; Steinseifer, Ulrich; Linkhorst, John; Wessling, MatthiasAdditive manufacturing of complex porous polymer geometries is a new field of advanced materials processing. Such new geometries can be used to fabricate porous polymer monoliths serving as a support for other material functions. Here, a novel fabrication technology to manufacture tailored 3D porous monoliths via additive manufacturing and templating is presented. The method is based on replicating a 3D-printed mold with a polymer solution of polyvinylidenfluorid-triethyl phosphate (PVDF-TEP) and induce phase separation of the polymer solution subsequently. In a second step, the mold is removed without affecting the porous PVDF phase. As a result, porous monoliths with a templated 3D architecture are successfully fabricated. The manufacturing process is successfully applied to complex structures and can be applied to any conceivable geometry. Coating the porous 3D monoliths with another PVDF solution allows applying a skin layer yielding an asymmetric membrane monolith. As a showcase, a polydimethylsiloxane coating even leads to a smooth and dense layer of micrometer size. The methodology enables a new generation of complex porous polymer monoliths with tailored surface coatings. For the combination of poly(dimethylsiloxane) on a porous support, gas/liquid mass transfer is used in blood oxygenation with reduced diffusion limitation is within reach.
- Item3D Printed Tubular Scaffolds with Massively Tailorable Mechanical Behavior(Weinheim : Wiley-VCH, 2022) Pickering, Edmund; Paxton, Naomi C.; Bo, Arixin; O’Connell, Bridget; King, Mitchell; Woodruff, Maria A.Melt electrowriting (MEW) is a promising additive manufacturing technique for tissue scaffold biofabrication. Successful application of MEW scaffolds requires strictly controlled mechanical behavior. This requires scaffold geometry be optimized to match native tissue properties while simultaneously supporting cell attachment and proliferation. The objective of this work is to investigate how geometric properties can be exploited to massively tailor the mechanical behavior of tubular crosshatch scaffolds. An experimentally validated finite element (FE) model is developed and 441 scaffold geometries are investigated under tension, compression, bending, and radial loading. A range of pore areas (4–150 mm2) and pore angles (11°–134°) are investigated. It is found that scaffold mechanical behavior is massively tunable through the control of these simple geometric parameters. Across the ranges investigated, scaffold stiffness varies by a factor of 294× for tension, 204× for compression, 231× for bending, and 124× for radial loading. Further, it is discussed how these geometric parameters can be simultaneously tuned for different biomimetic material applications. This work provides critical insights into scaffold design to achieve biomimetic mechanical behavior and provides an important tool in the development of biomimetic tissue engineered constructs.