Unidade de Investigação - CDRsp – Centro para o Desenvolvimento Rápido e Sustentado de Produto
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- 316L stainless steel mechanical and tribological behavior—A comparison between selective laser melting, hot pressing and conventional castingPublication . Bartolomeu, F.; Buciumeanu, M.; Pinto, E.; Alves, Nuno; Carvalho, O.; Silva, F: S.; Miranda, G.This work presents a comprehensive study on the influence of three different processing technologies (Selective Laser Melting, Hot Pressing and conventional casting) on the microstructure, mechanical and wear behavior of an austenitic 316L Stainless Steel.Acorrelation between the processing technologies,the obtained microstructure and the mechanical and wear behavior was achieved. The results showed that the highest mechanical properties and tribological performance were obtained for 316L SS specimens produced by Selective Laser Melting, when compared to Hot Pressing and conventional casting. The high wear and mechanical performance of 316L Stainless Steel fabricated by Selective Laser Melting are mainly due to the finer microstructure, induced by the process. In this sense, Selective Laser Melting seems a promising method to fabricate customized 316L SS implants with improved mechanical and wear performance
- 3D printing of new biobased unsaturated polyesters by microstereo-thermal-lithographyPublication . Gonçalves, Filipa A. M. M.; Costa, Cátia S. M. F.; Fabela, Inês G. P.; Farinha, Dina; Faneca, Henrique; Simões, Pedro N.; Serra, Arménio C.; Bártolo, Paulo J.; Coelho, Jorge F. J.New micro three-dimensional (3D) scaffolds using biobased unsaturated polyesters (UPs) were prepared by microstereo-thermal-lithography (μSTLG). This advanced processing technique offers indubitable advantages over traditional printing methods. The accuracy and roughness of the 3D structures were evaluated by scanning electron microscopy and infinite focus microscopy, revealing a suitable roughness for cell attachment. UPs were synthesized by bulk polycondensation between biobased aliphatic diacids (succinic, adipic and sebacic acid) and two different glycols (propylene glycol and diethylene glycol) using fumaric acid as the source of double bonds. The chemical structures of the new oligomers were confirmed by proton nuclear magnetic resonance spectra, attenuated total reflectance Fourier transform infrared spectroscopy and matrix assisted laser desorption/ionization-time of flight mass spectrometry. The thermal and mechanical properties of the UPs were evaluated to determine the influence of the diacid/glycol ratio and the type of diacid in the polyester's properties. In addition an extensive thermal characterization of the polyesters is reported. The data presented in this work opens the possibility for the use of biobased polyesters in additive manufacturing technologies as a route to prepare biodegradable tailor made scaffolds that have potential applications in a tissue engineering area.
- 3D shape prior active contours for an automatic segmentation of a patient specific femur from a CT scanPublication . Almeida, D.; Folgado, J.; Fernandes, P.R.; Ruben, RuiThe following paper describes a novel approach to a medical image segmentation problem. The fully automated computational procedure receives as input images from CT scan exams of the human femur and returns a three dimensional representation of the bone. This patient specific iterative approach is based in 3D active contours without edges, implemented over a level set framework, on which the evolution of the contour depends on local image parameters which can easily be defined by the user but also on a priori information about the volume to segment. This joint approach will lead to an optimal solution convergence of the iterative method. The resulting point cloud can be an excellent starting point for a Finite Element mesh generation and analysis or the basis for a stereolitography for example.
- Additive manufactured porous biomaterials targeting orthopedic implants: A suitable combination of mechanical, physical and topological propertiesPublication . Bartolomeu, F.; Dourado, N.; Pereira, F.; Alves, N.; Miranda, G.; Silva, F. S.Orthopedic implants are under incessant advancement to improve their interactions with surrounding bone tissue aiming to ensure successful outcomes for patients. A successful biological interaction between implant and surrounding bone depends on the combination of mechanical, physical and topological properties. Hence, Ti6Al4V cellular structures appear as very promising solutions towards the improvement of conventional orthopedic implants. This work addresses a set of fundamental tools that allow improving the design of Ti6Al4V cellular structures produced by Selective Laser Melting (SLM). Three-point bending tests were carried out to estimate the elastic modulus of the produced structures. Morphological analysis allowed to evaluate the dimensional differences that were noticed between the model CAD and the SLM structures. Finite element models (adjusted CAD) were constructed with the experimentally obtained dimensions to replicate the mechanical response of the SLM structures. Linear correlations were systematically found for the dimensions of the SLM structures as a function of the designed model CAD dimensions. This has also been observed for the measured porosities as a function of the designed CAD models. This data can be used in further FE analyses as design guidelines to help engineers fabricating near-net-shape SLM Ti6Al4V cellular structures. Besides, polished and sandblasted surface treatments performed on the Ti6Al4V cellular structures allowed to obtain suitable properties regarding roughness and wettability when compared to as-produced surfaces. The capillarity tests showed that all the analyzed Ti6Al4V structures are able to transport fluid along its structure. The cell viability tests demonstrate Ti6Al4V cellular structures SLM produced did not release toxic substances to the medium, indicating that these structures can assure a suitable environment for cells to proliferate and attach. This study proposes a design methodology for Ti6Al4V cellular structures, that owe suitable mechanical properties but also provide a proper combination of porosity, roughness, wettability, capillarity and cell viability, all of them relevant for orthopedic applications. A Ti6Al4V cellular structured hip implant prototype gathering the suitable features addressed in this study was successfully SLM-produced.
- An Additive Manufacturing Solution to Produce Big Green Parts from Tires and Recycled PlasticsPublication . Domingues, J.; Marques, T.; Mateus, A.; Carreira, P.; Malça, C.Recycling is crucial for the conservation and improvement of the environment. The reduction of natural resource exploration and recovery of waste are examples of actions to contribute to a sustainable development. Waste from end-of-life tires and undifferentiated plastics represents an environmental problem due to the very high number of tons of used tires and plastics produced, but with a high economic potential because their incorporation into high value-added products is an issue of utmost importance. The manufacturing technologies oriented to the increase in quality levels, functional advantages, structural and financial gains of the produced products are currently a hot topic in industry. Similarly, the use of additive manufacturing technologies, instead of conventional techniques, e.g. moulding to process materials obtained from waste recovery, is a great industrial challenge. In order to promote greater environmental responsibility and to present innovative solutions for the management and sustainable destination of used waste recovery from tires and undifferentiated plastics, a composite made from the blend of 60% of tire waste granulate and 40% of polypropylene (PP) recycled was tested with the final purpose of generating components with added value. Both waste recovery materials were used in the micronized state. The thermal and mechanical behaviours of the synthesized composite were studied through DSC/TGA analysis and tensile testing. The implementation of additive manufacturing methodologies to process the blends between used tires granulated with a high incorporation of wastes from undifferentiated plastics was also explored in this work in order to produce big green parts without mould needed, such as urban furniture.
- Advances in electrospun skin substitutesPublication . J.R. Dias; Granja, P.L.; Bártolo, P.J.In recent years, nanotechnology has received much attention in regenerative medicine, partly owing to the production of nanoscale structures that mimic the collagen fibrils of the native extracellular matrix. Electrospinning is a widely used technique to produce micro-nanofibers due its versatility, low cost and easy use that has been assuming an increasingly prominent position in the tissue engineering field. Electrospun systems have been especially investigated for wound dressings in skin regeneration given the intrinsic suitability of fibrous structures for that purpose. Several efforts have been made to combine distinct design strategies, synthetic and/or natural materials, fiber orientations and incorporation of substances (e.g. drugs, peptides, growth factors or other biomolecules) to develop an optimized electrospun wound dressing mimicking the native skin. This paper presents a comprehensive review on current and advanced electrospinning strategies for skin regeneration. Recent advances have been mainly focused on the materials used rather than on sophisticated fabrication strategies to generate biomimetic and complex constructs that resemble the mechanical and structural properties of the skin. The technological limitations of conventional strategies, such as random, aligned and core-shell technologies, and their poor mimicking of the native tissue are discussed. Advanced strategies, such as hybrid structures, cell and in situ electrospinning, are highlighted in the way they may contribute to circumvent the limitations of conventional strategies, through the combination of different technologies and approaches. The main research challenges and future trends of electrospinning for skin regeneration are discussed in the light of in vitro but mainly in vivo evidence.
- Application of a Hybrid Additive Manufacturing Methodology to Produce a Metal/Polymer Customized Dental ImplantPublication . Silva, M.; Felismina, R.; Mateus, A.; Parreira, P.; Malça, C.In this paper an integrated methodology for implants personalized manufacturing is presented. This methodology materializes the hybrid material implants manufacturing through the integration of two or more advanced Additive Manufacturing (AM) technologies. Furthermore, high strength biomechanical implants with optimized geometry and mass can be manufactured by biomimetic concepts application. The combination of polymers and ceramics or polymers and metal materials (or metal alloys) allows a significant leap in the development and production of a great diversity of components and applications. The combination of advanced additive manufacturing processes, e.g. the Selective Laser Melting (SLM) or Selective Laser Sintering (SLS) and the StereoLithography (SL), make possible the production of parts with almost unlimited geometric freedom and custom multimaterial. The manufacturing flexibility and the processing capacity of the different combinations of materials - metal/polymer - obtained from hybrid additive manufacturing systems - SLM/SL - are demonstrated here by the manufacture of a dental bridge implant.
- Ask not what additive manufacturing can do for youPublication . Gibson, I.The paraphrase of John F Kennedy’s famous words is for 2 purposes. Firstly it is to acknowledge that there are some people who have considered that it is a major part of their life’s work to promote Additive Manufacturing (AM) technology as primarily a selfless act. AM comprises an outstanding range of technology that should be brought to public attention as a true revolution in how we design and manufacture products. The second purpose is to show that technology development is only one part of this promotion process and that there are other ways in which we can get involved. This paper describes the author’s journey over the (approximately) 20 years since he was introduced to what was then called Rapid Prototyping (RP). It is not a catalogue of research and development projects but rather a list of activities that he has been involved in to help promote and support AM technology over these years. It will describe the conferences, activities, associations and publications that have been created to allow academics and professionals to describe and discuss their work amongst themselves and to the larger society.
- Bio-Materials and Prototyping Applications in MedicinePublication . Bártolo, Paulo Jorge; Bidanda, Bopaya; Bártolo, Paulo Jorge; Bidanda, BopayaThis second edition maintains a focus on integrated biomaterials, computer-aided design, and physical prototyping techniques as examples of the materials and applications that are found in medical environments. All original chapters, written by renowned experts in the field, have been updated along with the addition of four new chapters on: • Smart insoles • Medical applications of additive manufacturing • Additive manufacturing in craniofacial applications • Additive manufacturing in hearing aids This wide-ranging treatise on biomaterials and prototyping applications in medicine also focuses on solid freeform fabrication, rapid prototyping, layered manufacturing, and computer-aided design in the development of prosthetic devices. This book is a must-have for bioengineers seeking a comprehensive overview of this important subject and examples of medical applications, as well as researchers and academics in the same field.
- Bioengineered Temporomandibular Joint Disk Implants: Study Protocol for a Two-Phase Exploratory Randomized Preclinical Pilot Trial in 18 Black Merino Sheep (TEMPOJIMS)Publication . Ângelo, David Faustino; Monje, Florencio Gil; González-García, Raúl; Little, Christopher B; Mónico, Lisete; Pinho, Mário; Santos, Fábio Abade; Carrapiço, Belmira; Gonçalves, Sandra Cavaco; Morouço, Pedro; Alves, Nuno; Moura, Carla; Wang, Yadong; Jeffries, Eric; Gao, Jin; Sousa, Rita; Neto, Lia Lucas; Caldeira, Daniel; Salvado, FranciscoBackground: Preclinical trials are essential to test efficacious options to substitute the temporomandibular joint (TMJ) disk. The contemporary absence of an ideal treatment for patients with severe TMJ disorders can be related to difficulties concerning the appropriate study design to conduct preclinical trials in the TMJ field. These difficulties can be associated with the use of heterogeneous animal models, the use of the contralateral TMJ as control, the absence of rigorous randomized controlled preclinical trials with blinded outcomes assessors, and difficulties involving multidisciplinary teams. Objective: This study aims to develop a new, reproducible, and effective study design for preclinical research in the TMJ domain, obtaining rigorous data related to (1) identify the impact of bilateral discectomy in black Merino sheep, (2) identify the impact of bilateral discopexy in black Merino sheep, and (3) identify the impact of three different bioengineering TMJ discs in black Merino sheep. Methods: A two-phase exploratory randomized controlled preclinical trial with blinded outcomes is proposed. In the first phase, nine sheep are randomized into three different surgical bilateral procedures: bilateral discectomy, bilateral discopexy, and sham surgery. In the second phase, nine sheep are randomized to bilaterally test three different TMJ bioengineering disk implants. The primary outcome is the histological gradation of TMJ. Secondary outcomes are imaging changes, absolute masticatory time, ruminant time per cycle, ruminant kinetics, ruminant area, and sheep weight Results: Previous preclinical studies in this field have used the contralateral unoperated side as a control, different animal models ranging from mice to a canine model, with nonrandomized, nonblinded and uncontrolled study designs and limited outcomes measures. The main goal of this exploratory preclinical protocol is to set a new standard for future preclinical trials in oromaxillofacial surgery, particularly in the TMJ field, by proposing a rigorous design in black Merino sheep. The authors also intend to test the feasibility of pilot outcomes. The authors expect to increase the quality of further studies in this field and to progress in future treatment options for patients undergoing surgery for TMJ disk replacement. Conclusions: The study has commenced, but it is too early to provide results or conclusions.