Additive Manufacturing for Neurosurgery: Digital Light Processing of Individualized Patient-Specific Cerebral Aneurysms.

This study aims at demonstrating the feasibility of reproducing individualized patient-specific three-dimensional models of cerebral aneurysms by using the direct light processing (DLP) 3D printing technique in a low-time and inexpensive way. Such models were used to help neurosurgeons understand the anatomy of the aneurysms together with the surrounding vessels and their relationships, providing, therefore, a tangible supporting tool with which to train and plan surgical operations. The starting 3D models were obtained by processing the computed tomography angiographies and the digital subtraction angiographies of three patients. Then, a 3D DLP printer was used to print the models, and, if acceptable, on the basis of the neurosurgeon's opinion, they were used for the planning of the neurosurgery operation and patient information. All the models were printed within three hours, providing a comprehensive representation of the cerebral aneurysms and the surrounding structures and improving the understanding of their anatomy and simplifying the planning of the surgical operation.

Design and Mechanical Characterization of Voronoi Structures Manufactured by Indirect Additive Manufacturing.

Additive manufacturing (AM) is a production process for the fabrication of three-dimensional items characterized by complex geometries. Several technologies employ a localized melting of metal dust through the application of focused energy sources, such as lasers or electron beams, on a powder bed. Despite the high potential of AM, numerous burdens afflict this production technology; for example, the few materials available, thermal stress due to the focused thermal source, low surface finishing, anisotropic properties, and the high cost of raw materials and the manufacturing process. In this paper, the combination by AM of meltable resins with metal casting for an indirect additive manufacturing (I-AM) is proposed. The process is applied to the production of open cells metal foams, similar in shape to the products available in commerce. However, their cellular structure features were designed and optimized by graphical editor Grasshopper®. The metal foams produced by AM were cast with a lost wax process and compared with commercial metal foams by means of compression tests.

FIMEC Test to Evaluate the Water Uptake of Coated and Uncoated CFRP Composites.

This study focuses on the application of the FIMEC (flat-top cylinder indenter for mechanical characterization) indentation test to evaluate the effect of water uptake on the mechanical properties of high-performance materials, in particular CFRP (carbon fibre reinforced polymer) composites. Coated and uncoated samples were analyzed. Silicon-based and siloxane coatings were formulated and applied to CFRP to reduce the moisture absorption of the material. The FIMEC test was adopted to study the reduction of the stiffness of CFRP plates for different ageing in water. The evolution of mechanical properties is reported as a function of the water uptake. IR analyses and weight variation measures were used as supporting data. Experimental results show that the FIMEC test is suitable to assess the stiffness reduction due to the aging in water and to identify coatings able to minimize the water uptake.

Environmental and Economic Analysis of FDM, SLS and MJF Additive Manufacturing Technologies.

In this study, the authors present a comparative analysis of different additive manufacturing (AM) technologies for high-performance components. Four 3D printers, currently available on the Italian national manufacturing market and belonging to three different AM technologies, were considered. The analysis focused on technical aspects to highlight the characteristics and performance limits of each technology, economic aspects to allow for an assessment of the costs associated with the different processes, and environmental aspects to focus on the impact of the production cycles associated with these technologies on the ecosystem, resources and human health. This study highlighted the current limits of additive manufacturing technologies in terms of production capacity in the case of large-scale production of plastic components, especially large ones. At the same time, this study highlights how the geometry of the object to be developed greatly influences the optimal choice between the various AM technologies, in both technological and economic terms. Fused deposition modeling (FDM) is the technology that exhibits the greatest limitations hindering mass production due to production times and costs, but also due to the associated environmental impact.

Artificial Neural Network in Fibres Length Prediction for High Precision Control of Cellulose Refining.

Paper, a web of interconnected cellulose fibres, is widely used as a base substrate. It has been applied in several applications since it features interesting properties, such as renewability, biodegradability, recyclability, affordability and mechanical flexibility. Furthermore, it offers a broad possibility to modify its surface properties toward specifics additives. The fillers retention and the fibres bonding ability are heavily affected by the cellulose refining process that influences chemical and morphological features of the fibres. Several refining theories were developed in order to determine the best refining conditions. However, it is not trivial to control the cellulose refining as different phenomena occur simultaneously. Therefore, it is intuitively managed by experienced papermakers to improve paper structures and properties. An approach based on the machine learning aimed at estimating the effects of refining on the fibres morphology is proposed in this study. In particular, an artificial neural network (ANN) was implemented and trained with experimental data to predict the fibres length as a function of refining process variables. The prediction of this parameter is crucial to obtain a high-performance process in terms of effectiveness and the optimisation of the final product performance as a function of the process parameter. To achieve these results, data mining of the experimental patterns collected was exploited. It led to the achievement of excellent performance and high accuracy in fibres length prediction.

Improving Performance of an Open Cell Aluminium Foam through Electro-Deposition of Nickel.

The aim of this work is to investigate the mechanical performances and corrosion resistance of open-cell aluminium foams with an electroplated nickel coating. The influence of two different electrolytic solutions on mechanical properties and corrosion resistance was studied: The Watts solution (nickel sulphate-based solution) and a nickel sulphamate solution (widely adopted). Scanning electron microscopy and stereoscopic analysis allowed for the estimation of the coating uniformity and adhesion to the substrate. In order to assess the improvement of performances, compression and corrosion tests were performed on coated and uncoated foams. In addition, annealing was investigated in relation to different operational parameters, related both to electro-deposition (electrolyte, deposition current and time) and to annealing (treatment temperature). From the results, the yield stress and the corrosion resistance improved. Moreover, the annealing at increasing temperature was found to reduce the yield stress, but Ni-coated foams showed higher values of stress for all the considered treatment temperatures.

Al2O3 Coatings on Magnesium Alloy Deposited by the Fluidized Bed (FB) Technique.

Magnesium alloys are widely employed in several industrial domains for their outstanding properties. They have a high strength-weight ratio, with a density that is lower than aluminum (33% less), and feature good thermal properties, dimensional stability, and damping characteristics. However, they are vulnerable to oxidation and erosion-corrosion phenomena when applied in harsh service conditions. To avoid the degradation of magnesium, several coating methods have been presented in the literature; however, all of them deal with drawbacks that limit their application in an industrial environment, such as environmental pollution, toxicity of the coating materials, and high cost of the necessary machinery. In this work, a plating of Al2O3 film on a magnesium alloy realized by the fluidized bed (FB) technique and using alumina powder is proposed. The film growth obtained through this cold deposition process is analyzed, investigating the morphology as well as tribological and mechanical features and corrosion behavior of the plated samples. The resulting Al2O3 coatings show consistent improvement of the tribological and anti-corrosive performance of the magnesium alloy.

High Thermal Conductivity of Copper Matrix Composite Coatings with Highly-Aligned Graphite Nanoplatelets.

Nanocomposite coatings with highly-aligned graphite nanoplatelets in a copper matrix were successfully fabricated by electrodeposition. For the first time, the disposition and thermal conductivity of the nanofiller has been evaluated. The degree of alignment and inclination of the filling materials has been quantitatively evaluated by polarized micro-Raman spectroscopy. The room temperature values of the thermal conductivity were extracted for the graphite nanoplatelets by the dependence of the Raman G-peak frequency on the laser power excitation. Temperature dependency of the G-peak shift has been also measured. Most remarkable is the global thermal conductivity of 640 ± 20 W·m-1·K-1 (+57% of copper) obtained for the composite coating by the flash method. Our experimental results are accounted for by an effective medium approximation (EMA) model that considers the influence of filler geometry, orientation, and thermal conductivity inside a copper matrix.

In vitro and in vivo evaluation of diamond-coated strips.

OBJECTIVE: To test in vitro and in vivo the wear performance of diamond-coated strips by means of tribological testing and scanning electronic microscope (SEM). MATERIALS AND METHODS: To evaluate the in vitro wear performance, a tribological test was performed by a standard tribometer. The abrasive strips slid against stationary, freshly extracted premolars fixed in resin blocks, at a 2-newton load. At the end of the tribological test, the residual surface of the strip was observed by means of SEM analysis, which was performed every 50 meters until reaching 300 meters. For the in vivo analysis, the strip was used for 300 seconds, corresponding to 250 meters. RESULTS: The strips presented a fenestrated structure characterized by diamond granules alternating with voids. After the first 50 meters, it was possible to observe tooth material deposited on the surface of the strips and a certain number of abrasive grains detached. The surface of the strip after 250 meters appeared smoother and therefore less effective in its abrasive power. After 300 seconds of in vivo utilization of the strip, it was possible to observe the detachment of diamond abrasive grains, the near absence of the grains and, therefore, loss of abrasive power. CONCLUSIONS: Under ideal conditions, after 5 minutes (30 meters) of use, the strip loses its abrasive capacity by about 60%. In vivo, a more rapid loss of abrasive power was observed due to the greater load applied by the clinician in forcing the strip into the contact point.