Thermal Characterization of New 3D-Printed Bendable, Coplanar Capacitive Sensors.

In this paper a new low-cost stretchable coplanar capacitive sensor for liquid level sensing is presented. It has been 3D-printed by employing commercial thermoplastic polyurethane (TPU) and conductive materials and using a fused filament fabrication (FFF) process for monolithic fabrication. The sensor presents high linearity and good repeatability when measuring sunflower oil level. Experiments were performed to analyse the behaviour of the developed sensor when applying bending stimuli, in order to verify its flexibility, and a thermal characterization was performed in the temperature range from 10 °C to 40 °C to evaluate its effect on sunflower oil level measurement. The experimental results showed negligible sensitivity of the sensor to bending stimuli, whereas the thermal characterization produced a model describing the relationship between capacitance, temperature, and oil level, allowing temperature compensation in oil level measurement. The different temperature cycles allowed to quantify the main sources of uncertainty, and their effect on level measurement was evaluated.

Three-Dimensional Anthropometric Database of Attractive Caucasian Women: Standards and Comparisons.

The aim of this paper is to develop a database to determine a new biomorphometric standard of attractiveness. Sampling was carried out using noninvasive three-dimensional relief methods to measure the soft tissues of the face. These anthropometric measurements were analyzed to verify the existence of any canons with respect to shape, size, and measurement proportions which proved to be significant with regard to the aesthetics of the face. Finally, the anthropometric parameters obtained were compared with findings described in the international literature.The study sample was made up competitors in the Miss Italy 2010 and 2009 beauty contest. The three-dimensional (3D) scanning of soft tissue surfaces allowed 3D digital models of the faces and the spatial 3D coordinates of 25 anthropometric landmarks to be obtained and used to calculate linear and angular measurements. A paired Student t test for the analysis of the means allowed 3 key questions in the study of biomorphometric parameters of the face to be addressed through comparison with the data available in the literature.The question of statistical evidence for the samples analyzed being members of the populations samples reported in literature was also addressed.The critical analysis of the data helped to identify the anthropometric measurements of the upper, middle, and lower thirds of the face, variations in which have a major influence on the attractiveness of the face. These changes involve facial width, height, and depth. Changes in measurements of length, angles, and proportions found in the sample considered were also analyzed.

Noninvasive computerized scanning method for the correlation between the facial soft and hard tissues for an integrated three-dimensional anthropometry and cephalometry.

OBJECTIVES: The article describes a new methodology to scan and integrate facial soft tissue surface with dental hard tissue models in a three-dimensional (3D) virtual environment, for a novel diagnostic approach.The facial and the dental scans can be acquired using any optical scanning systems: the models are then aligned and integrated to obtain a full virtual navigable representation of the head of the patient. METHODS: In this article, we report in detail and further implemented a method for integrating 3D digital cast models into a 3D facial image, to visualize the anatomic position of the dentition. This system uses several 3D technologies to scan and digitize, integrating them with traditional dentistry records. The acquisitions were mainly performed using photogrammetric scanners, suitable for clinics or hospitals, able to obtain high mesh resolution and optimal surface texture for the photorealistic rendering of the face. To increase the quality and the resolution of the photogrammetric scanning of the dental elements, the authors propose a new technique to enhance the texture of the dental surface. RESULTS: Three examples of the application of the proposed procedure are reported in this article, using first laser scanning and photogrammetry and then only photogrammetry. Using cheek retractors, it is possible to scan directly a great number of dental elements. The final results are good navigable 3D models that integrate facial soft tissue and dental hard tissues. The method is characterized by the complete absence of ionizing radiation, portability and simplicity, fast acquisition, easy alignment of the 3D models, and wide angle of view of the scanner. CONCLUSIONS: This method is completely noninvasive and can be repeated any time the physician needs new clinical records. The 3D virtual model is a precise representation both of the soft and the hard tissue scanned, and it is possible to make any dimensional measure directly in the virtual space, for a full integrated 3D anthropometry and cephalometry. Moreover, the authors propose a method completely based on close-range photogrammetric scanning, able to detect facial and dental surfaces, and reducing the time, the complexity, and the cost of the scanning operations and the numerical elaboration.

One-Shot 3D Printed Soft Device Actuated Using Metal-Filled Channels and Sensed with Embedded Strain Gauge.

In this article, the multimaterial extrusion (M-MEX) technology is used to fabricate, in a single step, a three-dimensional printed soft electromagnetic (EM) actuator, based on internal channels, filled with soft liquid metal (Galinstan) and equipped with an embedded strain gauge, for the first time. At the state of the art, M-MEX techniques result underexploited for the manufacture of soft EM actuators: only traditional manufacturing approaches are used, resulting in many assembly steps. The main features of this work are as follows: (1) one shot fabrication, (2) smart structure equipped with sensor unit, and (3) scalability. The actuator was tested in conjunction with a commercial magnet, showing a bending angle of 22.4° (when activated at 4A), a relative error of 0.7%, and a very high sensor sensitivity of 49.7 Two more examples, showing all the potentialities of the proposed approach, are presented: a jumping frog-inspired soft robot and a dual independent two-finger actuator. This article aims to push the role of extrusion-based additive manufacturing for the fabrication of EM soft robots: several advantages such as portability, no cooling systems, fast responses, and noise reduction can be achieved by exploiting the proposed actuation system compared to the traditional and widespread actuation mechanisms (shape memory polymers, shape memory alloys, pneumatic actuation, and cable-driven actuation).

Additive Manufacturing for Bioinspired Structures: Experimental Study to Improve the Multimaterial Adhesion Between Soft and Stiff Materials.

The fabrication of bioinspired structures has recently gained an increasing popularity: mimicking the way in which nature develops structures is a vital prerequisite in soft robotics to achieve multiple benefits. Stiff structures connected by soft joints (recalling, for instance, human bones connected by cartilage) are highly appealing: several prototypes have been manufactured and tested, demonstrating their full potential. In the present research, the material extrusion (MEX) additive manufacturing technology has been used to manufacture stiff-soft bioinspired structures activated by shape memory alloy (SMA) actuators. First, three commercially available stiff composite plastic materials were investigated and linked to different 3D printing infills. Surprisingly, we found that the "gyroid" infill was correlated to the mechanical properties, demonstrating that it produces better results in terms of Young's modulus and ultimate tensile strength (UTS) than the widely studied "lines" infill. The primary focus of the research is an experimental study aimed at improving the adhesion at the interface between stiff and soft materials using an inexpensive method (i.e., MEX). Three different variables that have significant effects on the interface bonding were studied: (1) the interface geometry between stiff and soft parts, (2) the mesh overlapping process parameter, and (3) the annealing post-treatment. By optimizing the three variables, a Young's modulus of 48.8 MPa and a UTS of 3.8 MPa were achieved, when nylon+glass fiber (a stiff material) and thermoplastic polyurethane (a soft material) were 3D printed together. In particular, the 3.8 MPa UTS is 48% higher than the highest adhesion between the soft and stiff material (thermoplastic polyurethane [TPU] and acrylonitrile butadiene styrene) reported in literature. Finally, taking advantage of the improved stiff-soft adhesion, a bioinspired robotic finger has been fabricated and tested using an SMA actuator, showing an enormous potential for the proposed additive manufacturing approach in realizing bioinspired systems.

Accurate facial morphologic measurements using a 3-camera photogrammetric method.

OBJECTIVES: A new, low-cost photogrammetric method has been developed for facial morphometry applications. To evaluate the system, tests for the measurement and comparison of three-dimensional virtual faces were carried out in different subjects. MATERIALS AND METHODS: Twenty adult white Italian subjects, 10 men and 10 women, of ages ranging from 23 to 37 years, were included in this study. Three cameras were finely calibrated, and the point precision vector length was calculated, together with the quality parameters. For each subject, 3 different acquisitions were performed. A tessellated surface was obtained from each point cloud. The comparison was made by aligning three-dimensional information from different models. Differences between 2 different models were estimated by analysis of the distances. RESULTS: For the cases analyzed, the mean point precision overall root-mean-square vector length was 0.07 mm, with a SD of 0.027 mm. The results are reported for the system's capability of discriminating between the faces of different people. Results of comparisons between facial models of a single person were compared with those of comparisons between different subjects. Student's t-test revealed that the system was able to discriminate among different people, with a P > 95%. Two sex subgroups were formed: the mean error between subgroups ranged from 1.65 to 3.43 mm, and the mean ranged from 1.76 to 2.72 mm. CONCLUSIONS: The experiments confirmed the capabilities and the accuracy of the proposed photogrammetric system. Facial comparison was performed by analysis of distances on three-dimensional virtual models.

Analytical and Numerical Models of Thermoplastics: A Review Aimed to Pellet Extrusion-Based Additive Manufacturing.

Recent developments in additive manufacturing have moved towards a new trend in material extrusion processes (ISO/ASTM 52910:2018), dealing with the direct extrusion of thermoplastic and composite material from pellets. This growing interest is driven by the reduction of costs, environmental impact, energy consumption, and the possibility to increase the range of printable materials. Pellet additive manufacturing (PAM) can cover the same applications as fused filament fabrication (FFF), and in addition, can lead to scale towards larger workspaces that cannot be covered by FFF, due to the limited diameters of standard filaments. In the first case, the process is known as micro- or mini-extrusion (MiE) in the literature, in the second case the expression big area additive manufacturing (BAAM) is very common. Several models are available in literature regarding filament extrusion, while there is a lack of modeling of the extrusion dynamics in PAM. Physical and chemical phenomena involved in PAM have high overlap with those characterizing injection molding (IM). Therefore, a systematic study of IM literature can lead to a selection of the most promising models for PAM, both for lower (MiE) and larger (BAAM) extruder dimensions. The models concerning the IM process have been reviewed with this aim: the extraction of information useful for the development of codes able to predict thermo-fluid dynamics performances of PAM extruders.

Fused Filament Fabrication (FFF) for Manufacturing of Microfluidic Micromixers: An Experimental Study on the Effect of Process Variables in Printed Microfluidic Micromixers.

The need for accessible and inexpensive microfluidic devices requires new manufacturing methods and materials as a replacement for traditional soft lithography and polydimethylsiloxane (PDMS). Recently, with the advent of modern additive manufacturing (AM) techniques, 3D printing has attracted attention for its use in the fabrication of microfluidic devices and due to its automated, assembly-free 3D fabrication, rapidly decreasing cost, and fast-improving resolution and throughput. Here, fused filament fabrication (FFF) 3D printing was used to create microfluidic micromixers and enhance the mixing process, which has been identified as a challenge in microfluidic devices. A design of experiment (DoE) was performed on the effects of studied parameters in devices that were printed by FFF. The results of the colorimetric approach showed the effects of different parameters on the mixing process and on the enhancement of the mixing performance in printed devices. The presence of the geometrical features on the microchannels can act as ridges due to the nature of the FFF process. In comparison to passive and active methods, no complexity was added in the fabrication process, and the ridges are an inherent property of the FFF process.

Automated landmark extraction for orthodontic measurement of faces using the 3-camera photogrammetry methodology.

OBJECTIVES: To set up a three-dimensional photogrammetric scanning system for precise landmark measurements, without any physical contact, using a low-cost and noninvasive digital photogrammetric solution, for supporting several necessity in clinical orthodontics and/or surgery diagnosis. MATERIALS AND METHODS: Thirty coded targets were directly applied onto the subject's face on the soft tissue landmarks, and then, 3 simultaneous photos were acquired using photogrammetry, at room light conditions. For comparison, a dummy head was digitized both with a photogrammetric technique and with the laser scanner Minolta Vivid 910i (Konica Minolta, Tokyo, Japan). RESULTS: The precise measurement of the landmarks is ranged between 0.017 and 0.029 mm. The system automatically measures spatial position of face landmarks, from which distances and angles can be obtained. The facial measurements were compared with those done using laser scanning and manual caliper. The adopted method gives higher precision than the others (0.022-mm mean value on points and 0.038-mm mean value on linear distances on a dummy head), is simple, and can be used easily as a standard routine. CONCLUSIONS: The study demonstrated the validity of photogrammetry for accurate digitization of human face landmarks. This research points out the potential of this low-cost photogrammetry approach for medical digitization.

Additive Manufacturing for Soft Robotics: Design and Fabrication of Airtight, Monolithic Bending PneuNets with Embedded Air Connectors.

Air tightness is a challenging task for 3D-printed components, especially for fused filament fabrication (FFF), due to inherent issues, related to the layer-by-layer fabrication method. On the other hand, the capability of 3D print airtight cavities with complex shapes is very attractive for several emerging research fields, such as soft robotics. The present paper proposes a repeatable methodology to 3D print airtight soft actuators with embedded air connectors. The FFF process has been optimized to manufacture monolithic bending PneuNets (MBPs), an emerging class of soft robots. FFF has several advantages in soft robot fabrication: (i) it is a fully automated process which does not require manual tasks as for molding, (ii) it is one of the most ubiquitous and inexpensive (FFF 3D printers costs < $200) 3D-printing technologies, and (iii) more materials can be used in the same printing cycle which allows embedding of several elements in the soft robot body. Using commercial soft filaments and a dual-extruder 3D printer, at first, a novel air connector which can be easily embedded in each soft robot, made via FFF technology with a single printing cycle, has been fabricated and tested. This new embedded air connector (EAC) prevents air leaks at the interface between pneumatic pipe and soft robot and replaces the commercial air connections, often origin of leakages in soft robots. A subsequent experimental study using four different shapes of MBPs, each equipped with EAC, showed the way in which different design configurations can affect bending performance. By focusing on the best performing shape, among the tested ones, the authors studied the relationship between bending performance and air tightness, proving how the Design for Additive Manufacturing approach is essential for advanced applications involving FFF. In particular, the relationship between chamber wall thickness and printing parameters has been analyzed, the thickness of the walls has been studied from 1.6 to 1 mm while maintaining air tightness and improving the bending angle by 76.7% under a pressure of 4 bar. It emerged that the main printing parameter affecting chamber wall air tightness is the line width that, in conjunction with the wall thickness, can ensure air tightness of the soft actuator body.

Mechanobiological Approach to Design and Optimize Bone Tissue Scaffolds 3D Printed with Fused Deposition Modeling: A Feasibility Study.

In spite of the rather large use of the fused deposition modeling (FDM) technique for the fabrication of scaffolds, no studies are reported in the literature that optimize the geometry of such scaffold types based on mechanobiological criteria. We implemented a mechanobiology-based optimization algorithm to determine the optimal distance between the strands in cylindrical scaffolds subjected to compression. The optimized scaffolds were then 3D printed with the FDM technique and successively measured. We found that the difference between the optimized distances and the average measured ones never exceeded 8.27% of the optimized distance. However, we found that large fabrication errors are made on the filament diameter when the filament diameter to be realized differs significantly with respect to the diameter of the nozzle utilized for the extrusion. This feasibility study demonstrated that the FDM technique is suitable to build accurate scaffold samples only in the cases where the strand diameter is close to the nozzle diameter. Conversely, when a large difference exists, large fabrication errors can be committed on the diameter of the filaments. In general, the scaffolds realized with the FDM technique were predicted to stimulate the formation of amounts of bone smaller than those that can be obtained with other regular beam-based scaffolds.

Bioengineering Bone Tissue with 3D Printed Scaffolds in the Presence of Oligostilbenes.

Diseases determining bone tissue loss have a high impact on people of any age. Bone healing can be improved using a therapeutic approach based on tissue engineering. Scientific research is demonstrating that among bone regeneration techniques, interesting results, in filling of bone lesions and dehiscence have been obtained using adult mesenchymal stem cells (MSCs) integrated with biocompatible scaffolds. The geometry of the scaffold has critical effects on cell adhesion, proliferation and differentiation. Many cytokines and compounds have been demonstrated to be effective in promoting MSCs osteogenic differentiation. Oligostilbenes, such as Resveratrol (Res) and Polydatin (Pol), can increase MSCs osteoblastic features. 3D printing is an excellent technique to create scaffolds customized for the lesion and thus optimized for the patient. In this work we analyze osteoblastic features of adult MSCs integrated with 3D-printed polycarbonate scaffolds differentiated in the presence of oligostilbenes.

On the Impact of the Fabrication Method on the Performance of 3D Printed Mixers.

A wide variety of 3D printing technologies have been used for the fabrication of lab-on-a-chip (LOC) devices in recent years. Despite the large number of studies having examined the use of 3D printing technologies in microfluidic devices, the effect of the fabrication method on their performance has received little attention. In this paper, a comparison is shown between unibody-LOC micro-mixers, a particular type of monolithic design for 3D printed LOCs, fabricated in polyjet, stereolithography (SLA) and fused deposition modelling (FDM or FFF) platforms, paying particular attention to the inherent limitations of each fabrication platform and how these affect the performance of the manufactured devices.

Investigating the Potential of Commercial-Grade Carbon Black-Filled TPU for the 3D Printing of Compressive Sensors.

The present research aims to exploit commercially available materials and machines to fabricate multilayer, topologically designed transducers, which can be embedded into mechanical devices, such as soft or rigid grippers. Preliminary tests on the possibility of fabricating 3D-printed transducers using a commercial conductive elastomeric filament, carbon black-filled thermoplastic polyurethane, are presented. The commercial carbon-filled thermoplastic polyurethane (TPU), analyzed in the present paper, has proven to be a candidate material for the production of 3D printed displacement sensors. Some limitations in fabricating the transducers from a 2.85 mm filament were found, and comparisons with 1.75 mm filaments should be conducted. Moreover, further research on the low repeatability at low displacements and the higher performance of the hollow structure, in terms of repeatability, must be carried out. To propose an approach that can very easily be reproduced, only commercial filaments are used.

Analysis of Shape Geometry and Roughness of Ti6Al4V Parts Fabricated by Nanosecond Laser Ablation.

Laser milling is a micro-machining process that uses a laser beam as a tool to remove material through the layer-by-layer ablation mechanism. Generally in laser ablation, the quality of parts is reduced by melt accretions and thermal damage; therefore, this problem is reduced with shorter pulse duration, although ablation efficiency decreases as well. Thus, laser ablation in the nanosecond range still offers a good compromise between process quality and efficiency. Therefore, laser milling with nanosecond laser ablation requires an accurate study to reduce geometric defects induced by the process. The aim of this paper was to study the shape geometry and roughness of Ti6Al4V parts fabricated by laser milling using a nanosecond Nd:YAG laser source. The impact of the laser processing parameters on machining outcomes was studied in order to determine the optimized processing conditions for reducing geometrical defects and improving surface quality. In particular, the influence of average laser power, frequency, and scanning speed was investigated. The geometry of micro-parts was revealed using a 3D digitizing system, the Optimet Mini Conoscan 4000, which combines a non-contact, single-point measuring sensor based on conoscopic holography technology. The use of this measurement technology yielded complete information of the shape geometry and dimensions of the built parts. In addition, the roughness of manufactured surfaces was assessed to complete the analysis.

Extrusion-Based 3D Printing of Microfluidic Devices for Chemical and Biomedical Applications: A Topical Review.

One of the most widespread additive manufacturing (AM) technologies is fused deposition modelling (FDM), also known as fused filament fabrication (FFF) or extrusion-based AM. The main reasons for its success are low costs, very simple machine structure, and a wide variety of available materials. However, one of the main limitations of the process is its accuracy and finishing. In spite of this, FDM is finding more and more applications, including in the world of micro-components. In this world, one of the most interesting topics is represented by microfluidic reactors for chemical and biomedical applications. The present review focusses on this research topic from a process point of view, describing at first the platforms and materials and then deepening the most relevant applications.

Application of off-the-shelf stereo-cameras for the 3D assessment of morphometric variations caused by rhinoplasty.

The present paper shows how a non-invasive and low-cost photogrammetric stereo device allows the assessment of morphometric variations of the nose following rhinoplasty. Six female patients, aged between 24 and 37 years, underwent 3D stereo-photogrammetric scanning. Three-dimensional computerised models were generated, extracting also information related to the coordinates of facial landmarks, distances between landmarks, angles, in pre- and postoperative situation. Two kinds of analysis were carried out: (i) statistical correlation between size variations and (ii) morphometric analysis, including General Procrustes Analysis (GPA), Principal Components Analysis (PCA) and Warping. The study shows the usefulness of the stereo-photogrammetric facial digitisation for morphometric analysis of the human face. Three-dimensional computerised models are also an important tool for the assessment of the surgeon's performance in the event of dispute between doctor and patient. Moreover, confirmation of the PCA as an analytical tool for the identification of components characterising the morphometric structure of the nose is highlighted.

Is principal component analysis an effective tool to predict face attractiveness? A contribution based on real 3D faces of highly selected attractive women, scanned with stereophotogrammetry.

In the literature, several papers report studies on mathematical models used to describe facial features and to predict female facial beauty based on 3D human face data. Many authors have proposed the principal component analysis (PCA) method that permits modeling of the entire human face using a limited number of parameters. In some cases, these models have been correlated with beauty classifications, obtaining good attractiveness predictability using wrapped 2D or 3D models. To verify these results, in this paper, the authors conducted a three-dimensional digitization study of 66 very attractive female subjects using a computerized noninvasive tool known as 3D digital photogrammetry. The sample consisted of the 64 contestants of the final phase of the Miss Italy 2010 beauty contest, plus the two highest ranked contestants in the 2009 competition. PCA was conducted on this real faces sample to verify if there is a correlation between ranking and the principal components of the face models. There was no correlation and therefore, this hypothesis is not confirmed for our sample. Considering that the results of the contest are not only solely a function of facial attractiveness, but undoubtedly are significantly impacted by it, the authors based on their experience and real faces conclude that PCA analysis is not a valid prediction tool for attractiveness. The database of the features belonging to the sample analyzed are downloadable online and further contributions are welcome.

Three-dimensional methodology for photogrammetric acquisition of the soft tissues of the face: a new clinical-instrumental protocol.

BACKGROUND: The objective of this study is to define an acquisition protocol that is clear, precise, repeatable, simple, fast and that is useful for analysis of the anthropometric characteristics of the soft tissue of the face. METHODS: The analysis was carried out according to a new clinical-instrumental protocol that comprises four distinct phases: (1) setup of portable equipment in the space in which field analysis will be performed, (2) preparation of the subject and spatial positioning, (3) scanning of the subject with different facial expressions, and (4) treatment and processing of data. The protocol was tested on a sample comprising 66 female subjects (64 Caucasian, 1 Ethiopian, and 1 Brazilian) who were the finalists of an Italian national beauty contest in 2010. To illustrate the potential of the method, we report here the measurements and full analysis that were carried out on the facial model of one of the subjects who was scanned. RESULTS: This new protocol for the acquisition of faces is shown to be fast (phase 1, about 1 h; phase 2, about 1.5 min; phase 3, about 1.5 min; phase 4, about 15 min), simple (phases 1 to 3 requiring a short operator training period; only phase 4 requires expert operators), repeatable (with direct palpation of anatomical landmarks and marking of their positions on the face, the problem of identification of these same landmarks on the digital model is solved), reliable and precise (average precision of measurements, 0.5 to 0.6 mm over the entire surface of the face). CONCLUSIONS: This standardization allows the mapping of the subjects to be carried out following the same conditions in a reliable and fast process for all of the subjects scanned.