Gender differences in ethmoid sinus morphology_ 3D reconstruction of computed tomographic images.

BACKGROUND: The ethmoid sinus (ES) is a three-dimensional (3D) complex structure, a clear understanding of the ES anatomy is helpful to plan intranasal surgery. However, most prior studies use 2D measurements, which may not accurately depict the 3D structure. The current study measured the gender differences in ES morphology based on 3D reconstruction of computed tomography (CT) images. METHODS: The 3D models were reconstructed using CT images. Twenty-one males and 15 females were enrolled in the study. The ES dimensions, including width, height and aspect ratio (AR) of each cutting-plane section, were measured at 10% increments along with the anteroposterior axis of the ES. The gender differences in the above parameters were further evaluated by an independent t-test. RESULTS: The width of the ES for males is 12.0 ± 2.1 mm, which was significantly greater than that in females (10.0 ± 2.1 mm). The average height for males is 18.4 ± 3.5 mm, and 18.2 ± 3.4 mm for females. The AR of female (male) is around 0.56 (0.63) for the anterior ES and 0.66 (0.75) for the posterior. There are significant differences between genders in the parameters of width and AR (p < 0.05). CONCLUSION: This study found that the aspect ratio greatly varies along the length of ES, indicating that the cross-section of the ES in the anterior is closer to an elliptical shape and turns closer to a circular shape near its posterior. There is a significant difference between genders in width and aspect ratio. The results would be helpful to know the complex anatomic details of the ethmoid sinus.

Development of a quasi-collimated UV LED backlight for producing uniform and smooth 3D printing objects.

3D printing techniques have great potential in the direct fabrication of microfluidic and many kinds of molds, such as dental and jewelry models. However, the resolution, surface roughness, and critical dimension uniformity of 3D printing objects are still a challenge for improvement. In this article, we proposed a 405nm light emitting diode (LED) backlight module based on stacks of structured films, and the full width half maximum (FWHM) of the angular distribution of this module is reduced to less than ± 15°. Compared with the commercial lens array optical module, the ten points intensity uniformity of an 8.9" build area is improved from 56% to 80%. Moreover, we found that the surface roughness and the sharpness of the edge of the printing objects are also obviously improved by our novel quasi-collimated LED backlight module. These features give us a promising way for the application of microfluidics and micro-optics components in the future.

High-precision miniaturized low-cost reflective grating laser encoder with nanometric accuracy.

This paper presents a novel optical encoder, M-encoder, which can be used within high-precision metrology systems based on the technology of customized prism and homodyne detection. The M-encoder is an exposed encoder measuring reflective glass and metal scale, which is targeting the biggest area of the encoder market, 20 µm pitch, and has a resolution under 100 nm. The error of 23 nm for 100 mm traveling distance has been measured. The applied technology has successfully improved alignment tolerances, in which the tolerance of installation achieved to ±0.5∘, ±0.5∘, and ±1∘ for pitch, yaw, and roll angle, respectively. The accuracy of results has been verified by comparing them with one of the commercial encoders and also by using an HP interferometer. The results show the resolution and accuracy can be compatible with the market products. In addition, a new method of grating calibration has been described based on the Littrow configuration, and the pitch of the fabricated scale by a femtosecond laser has been measured with the accuracy of 2 nm.

Investigating the Effect of Design Parameters on the Mechanical Performance of Contact Wave Springs Designed for Additive Manufacturing.

Additive manufacturing (AM) enables design freedom to fabricate functionally graded wave springs designed by varying design parameters, which are not possible in traditional manufacturing. AM also enables optimization of the wave spring design for specific load-bearing requirements. Existing wave springs are manufactured by metal with constant dimensions (width and thickness of the strip, diameter) using customized traditional machines in which design variations are almost impossible. This study aims to investigate the effect of wave height, the overlap between the two consecutive coils, and the number of waves per coil on the mechanical properties, for example, load-bearing capacity, stiffness, and energy absorption of contact wave springs. Two designs, that is, rectangular and variable thickness wave springs, were chosen and the design of experiment was devised using Minitab software, resulting in 24 samples. HP MultiJet Fusion (MJF) printer was used to manufacture the samples for performing uniaxial compression tests up to 10 cycles and 90% of the compressible distance to study the variation in mechanical properties due to changes in parameters. Experimental and simulation results showed that variable thickness wave springs have better load bearing, stiffness, and energy absorption compared with the rectangular counterparts. In addition to that, the number of waves per coil and the overlap are directly proportional to the load-bearing capacity as well as stiffness of the wave springs, while the constant wave height is responsible for more uniformly distributed stresses throughout the coils. Load-bearing capacity was increased by 62%, stiffness by 37%, and energy absorption by 20% once the number of waves per coil is increased from 5 to 6 in rectangular wave springs. Overall, the parametric variations significantly affect the performance of wave springs; thus, designers can choose the optimized values of investigated parameters to design customized wave springs for specific applications as per load/stiffness requirements.

Flexural Properties of Periodic Lattice Structured Lightweight Cantilever Beams Fabricated Using Additive Manufacturing: Experimental and Finite Element Methods.

Lattice structures are a type of lightweight structure that is more commonly being applied to engineering systems as a way to reduce mass and enhance mechanical properties. The cantilever beam case is one of the primary modes of loading in many engineering applications, where light-weighting is also crucial. However, lightweight lattice structured cantilever beams have not been investigated considerably due to design and manufacturing limitations. Therefore, the aim of this study was to investigate the response of four different lattice structured cantilever beams comprising of unit cells made from Schwarz-P, Schwarz-D, Gyroid, and Octet-truss structures fabricated using Multi Jet Fusion additive manufacturing technology. An investigation into the cross-sections of these structures leads to a conclusion that the beams made from such structures are non-prismatic in nature as a result of variation in cross-sections. This led to the development of equations for the moment of inertia of these structures, which helped in calculating symmetric and un-symmetric bending. These beams were subjected to cantilever loading until failure, which provided insights into flexural properties such as flexural stress, stiffness, and strain energy. Experimental results indicate that the surface-based structures, due to better surface-area-to-volume ratio, have better ability in transferring loads and hence perform better than the beam-based Octet-truss beam. The Schwarz-D beam had performed the best among all the beams, which is further supported in literature due to its stretch-dominated topology that results in higher values of modulus. The finite element analysis (FEA) findings also validate these findings in which the distribution of stresses can be seen to be better transmitted than the other structures. The FEA validation shows that the distribution of Von-Mises stress and their position in experimental tests and failure of these structures is also very close, which provides validation to the experimental setup and the testing of beams.

A Review of Critical Issues in High-Speed Vat Photopolymerization.

Vat photopolymerization (VPP) is an effective additive manufacturing (AM) process known for its high dimensional accuracy and excellent surface finish. It employs vector scanning and mask projection techniques to cure photopolymer resin at a specific wavelength. Among the mask projection methods, digital light processing (DLP) and liquid crystal display (LCD) VPP have gained significant popularity in various industries. To upgrade DLP and LCC VPP into a high-speed process, increasing both the printing speed and projection area in terms of the volumetric print rate is crucial. However, challenges arise, such as the high separation force between the cured part and the interface and a longer resin refilling time. Additionally, the divergence of the light-emitting diode (LED) makes controlling the irradiance homogeneity of large-sized LCD panels difficult, while low transmission rates of near ultraviolet (NUV) impact the processing time of LCD VPP. Furthermore, limitations in light intensity and fixed pixel ratios of digital micromirror devices (DMDs) constrain the increase in the projection area of DLP VPP. This paper identifies these critical issues and provides detailed reviews of available solutions, aiming to guide future research towards developing a more productive and cost-effective high-speed VPP in terms of the high volumetric print rate.

Energy Absorption and Stiffness of Thin and Thick-Walled Closed-Cell 3D-Printed Structures Fabricated from a Hyperelastic Soft Polymer.

This study analyses the energy absorption and stiffness behaviour of 3D-printed supportless, closed-cell lattice structures. The unit cell design is bioinspired by the sea urchin morphology having organism-level biomimicry. This gives rise to an open-cell lattice structure that can be used to produce two different closed-cell structures by closing the openings with thin or thick walls, respectively. In the design phase, the focus is placed on obtaining the same relative density with all structures. The present study demonstrates that closure of the open-cell lattice structure enhances the mechanical properties without affecting the functional requirements. Thermoplastic polyurethane (TPU) is used to produce the structures via additive manufacturing (AM) using fused filament fabrication (FFF). Uniaxial compression tests are performed to understand the mechanical and functional properties of the structures. Numerical models are developed adopting an advanced material model aimed at studying the hysteretic behaviour of the hyperelastic polymer. The study strengthens design principles for closed-cell lattice structures, highlighting the fact that a thin membrane is the best morphology to enhance structural properties. The results of this study can be generalised and easily applied to applications where functional requirements are of key importance, such as in the production of lightweight midsole shoes.

Design for Additive Manufacturing and Investigation of Surface-Based Lattice Structures for Buckling Properties Using Experimental and Finite Element Methods.

Additive Manufacturing (AM) is rapidly evolving due to its unlimited design freedom to fabricate complex and intricate light-weight geometries with the use of lattice structure that have potential applications including construction, aerospace and biomedical applications, where mechanical properties are the prime focus. Buckling instability in lattice structures is one of the main failure mechanisms that can lead to major failure in structural applications that are subjected to compressive loads, but it has yet to be fully explored. This study aims to investigate the effect of surface-based lattice structure topologies and structured column height on the critical buckling load of lattice structured columns. Four different triply periodic minimal surface (TPMS) lattice topologies were selected and three design configurations (unit cells in x, y, z axis), i.e., 2 × 2 × 4, 2 × 2 × 8 and 2 × 2 × 16 column, for each structure were designed followed by printing using HP MultiJet fusion. Uni-axial compression testing was performed to study the variation in critical buckling load due to change in unit cell topology and column height. The results revealed that the structured column possessing Diamond structures shows the highest critical buckling load followed by Neovius and Gyroid structures, whereas the Schwarz-P unit cell showed least resistance to buckling among the unit cells analyzed in this study. In addition to that, the Diamond design showed a uniform decrease in critical buckling load with a column height maximum of 5193 N, which makes it better for applications in which the column's height is relatively higher while the Schwarz-P design showed advantages for low height column maximum of 2271 N. Overall, the variations of unit cell morphologies greatly affect the critical buckling load and permits the researchers to select different lattice structures for various applications as per load/stiffness requirement with different height and dimensions. Experimental results were validated by finite element analysis (FEA), which showed same patterns of buckling while the numerical values of critical buckling load show the variation to be up to 10%.

Mechanical Performance of Lightweight-Designed Honeycomb Structures Fabricated Using Multijet Fusion Additive Manufacturing Technology.

Cellular structures including three-dimensional lattices and two-dimensional honeycombs have significant benefits in achieving optimal mechanical performance with light weighting. Recently developed design techniques integrated with additive manufacturing (AM) technologies have enhanced the possibility of fabricating intricate geometries such as honeycomb structures. Generally, failure initiates from the sharp edges in honeycomb structures, which leads to a reduction in stiffness and energy absorption performance. By material quantity, these hinges account for a large amount of material in cells. Therefore, redesigning of honeycomb structures is needed, which can improve aforementioned characteristics. However, this increases the design complexity of honeycombs, such that novel manufacturing techniques such as AM has to be employed. This research attempts to investigate the optimal material distribution of three different topologies of honeycomb structures (hexagonal, triangular, and square) with nine different design configurations. To achieve this, higher amount of material was distributed at nodes in the form of fillets while keeping overall weight of the structure constant. Furthermore, these design configurations were analyzed in terms of stiffness, energy absorption, and the failure behavior by performing finite element analysis and experimental tests on the samples manufactured using Multijet fusion AM technology. It was found that adding material to the edges can improve the mechanical properties of honeycombs such as stiffness and energy absorption efficiency. Furthermore, the failure mechanism is changed due to redistribution of material in the structure. The design configurations without fillets suffer from brittle failure at the start of the plastic deformation, whereas the configurations with increased material proportion at the nodes have larger plastic deformation zones, which improves the energy absorption efficiency.

Supportless Lattice Structure for Additive Manufacturing of Functional Products and the Evaluation of Its Mechanical Property at Variable Strain Rates.

This study proposes an innovative design solution based on the design for additive manufacturing (DfAM) and post-process for manufacturing industrial-grade products by reducing additive manufacturing (AM) time and improving production agility. The design of the supportless open cell Sea Urchin lattice structure is analyzed using DfAM for material extrusion (MEX) process to print support free in any direction. The open cell is converted into a global closed cell to entrap secondary foam material. The lattice structure is 3D printed with Polyethylene terephthalate glycol (PETG) material and is filled with foam using the Hybrid MEX process. Foam-filling improves the lattice structure's energy absorption and crash force efficiency when tested at different strain rates. An industrial case study demonstrates the importance and application of this lightweight and tough design to meet the challenging current and future mass customization market. A consumer-based industrial scenario is chosen wherein an innovative 3D-printed universal puck accommodates different shapes of products across the supply line. The pucks are prone to collisions on the supply line, generating shock loads and hazardous noise. The results show that support-free global closed-cell lattice structures filled with foam improve energy absorption at a high strain rate and enhance the functional requirement of noise reduction during the collision.

Investigation of Compression and Buckling Properties of a Novel Surface-Based Lattice Structure Manufactured Using Multi Jet Fusion Technology.

Lattice structures possess many superior properties over solid materials and conventional structures. Application-oriented lattice structure designs have become a choice in many industries, such as aerospace, automotive applications, construction, biomedical applications, and footwear. However, numerical and empirical analyses are required to predict mechanical behavior under different boundary conditions. In this article, a novel surface-based structure named O-surface structure is designed and inspired by existing Triply Periodic Minimal Surface morphologies in a particular sea urchin structure. For comparison, both structures were designed with two different height configurations and investigated for mechanical performance in terms of compression, local buckling, global buckling, and post-buckling behavior. Both simulation and experimental methods were carried out to reveal these aforementioned properties of samples fabricated by multi jet fusion technology. The sea urchin structure exhibited better mechanical strength than its counterpart, with the same relative density almost two-folds higher in the compressive response. However, the O-surface structure recorded more excellent energy absorption and flexible behavior under compression. Additionally, the compression behavior of the O-surface structure was progressive from top to bottom. In contrast, the sea urchin structure was collapsed randomly due to originated cracks from unit cells' centers with local buckling effects. Moreover, the buckling direction of structures in long columns was also affected by keeping the relative density constant. Finally, based on specific strength, the O-surface structure exhibited 16-folds higher specific strength than the sea urchin structure.

The Effect of Functional Gradient Material Distribution and Patterning on Torsional Properties of Lattice Structures Manufactured Using MultiJet Fusion Technology.

Functionally graded lattice structures have attracted much attention in engineering due to their excellent mechanical performance resulting from their optimized and application-specific properties. These structures are inspired by nature and are important for a lightweight yet efficient and optimal functionality. They have enhanced mechanical properties over the uniform density counterparts because of their graded design, making them preferable for many applications. Several studies were carried out to investigate the mechanical properties of graded density lattice structures subjected to different types of loadings mainly related to tensile, compression, and fatigue responses. In applications related to biomedical, automotive, and aerospace sectors, dynamic bending and rotational stresses are critical load components. Therefore, the study of torsional properties of functionally gradient lattice structures will contribute to a better implementation of lattice structures in several sectors. In this study, several functionally gradient triply periodic minimal surfaces structures and strut-based lattice structures were designed in cylindrical shapes having 40% relative density. The HP Multi Jet Fusion 4200 3D printer was used to fabricate all specimens for the experimental study. A torsional experiment until the failure of each structure was conducted to investigate properties of the lattice structures such as torsional stiffness, energy absorption, and failure characteristics. The results showed that the stiffness and energy absorption of structures can be improved by an effective material distribution that corresponds to the stress concentration due to torsional load. The TPMS based functionally gradient design showed a 35% increase in torsional stiffness and 15% increase in the ultimate shear strength compared to their uniform counterparts. In addition, results also revealed that an effective material distribution affects the failure mechanism of the lattice structures and delays the plastic deformation, increasing their resistance to torsional loads.

Effect of Fillets on Mechanical Properties of Lattice Structures Fabricated Using Multi-Jet Fusion Technology.

Cellular structures with tailored topologies can be fabricated using additive manufacturing (AM) processes to obtain the desired global and local mechanical properties, such as stiffness and energy absorption. Lattice structures usually fail from the sharp edges owing to the high stress concentration and residual stress. Therefore, it is crucial to analyze the failure mechanism of lattice structures to improve the mechanical properties. In this study, several lattice topologies with fillets were designed, and the effects of the fillets on the stiffness, energy absorption, energy return, and energy loss of an open-cell lattice structure were investigated at a constant relative density. A recently developed high-speed AM multi-jet fusion technology was employed to fabricate lattice samples with two different unit cell sizes. Nonlinear simulations using ANSYS software were performed to investigate the mechanical properties of the samples. Experimental compression and loading-unloading tests were conducted to validate the simulation results. The results showed that the stiffness and energy absorption of the lattice structures can be improved significantly by the addition of fillets and/or vertical struts, which also influence other properties such as the failure mechanism and compliance. By adding the fillets, the failure location can be shifted from the sharp edges or joints to other regions of the lattice structure, as observed by comparing the failure mechanisms of type B and C structures with that of the type A structure (without fillets). The results of this study suggest that AM software designers should consider filleted corners when developing algorithms for generating various types of lattice structures automatically. Additionally, it was found that the accumulation of unsintered powder in the sharp corners of lattice geometries can also be minimized by the addition of fillets to convert the sharp corners to curved edges.

Supportless Lattice Structures for Energy Absorption Fabricated by Fused Deposition Modeling.

Additively manufactured cellular structures represent a promising engineering design concept for making customized products where user-specific mechanical properties are required. One of the major challenges in the additive manufacturing (AM) process is removal of unwanted support structures from the lattice. The support structure consumes extra material, printing time, and energy for manufacturing. Postprinting, it needs extensive postprocessing work to remove it from the lattice structure chemically or mechanically. In the case of flexible materials such as thermoplastic polyurethane (TPU), removing the support structure from the lattice is very difficult with the material extrusion process. In this article, a new type of a shell-shaped lattice structure inspired by sea urchin (SU) morphology is designed. This lattice can be additively manufactured by material extrusion processes such as fused deposition modeling (FDM) without requiring any support structures. The mechanical properties of the proposed structure, such as stiffness and energy absorption during loading and unloading, have been evaluated as they are important for cushioning. The compressive results indicate that the stiffness property is almost twice as high compared with the benchmarked, bending-dominated, body-centered cubic (BCC) lattice structure of the same relative density and ethylene vinyl acetate (EVA) foam. Energy absorption is almost equal to the BCC lattice and 20% better than EVA foam. Last, a predictive model on stiffness behavior and energy return was developed to facilitate a systematic way to select optimal densities of the SU lattice structure for energy-absorbing applications. Visual inspection has also revealed that there is no sagging or failure of the lattice, which reduced the manufacturing time and postprocessing time, saving a significant amount of material without compromising on quality. Supportless lattice printing was also validated by printing the specimen with a different FDM printer and TPU filament. A possible application for supportless lattice structures can be for AM of customized shoe midsoles at low cost, ski boots, tires, automotive crush boxes, or any other energy-absorbing structures.

Buckling and Post-Buckling Behavior of Uniform and Variable-Density Lattice Columns Fabricated Using Additive Manufacturing.

Lattice structures are known for their high strength-to-weight ratio, multiple functionalities, lightweight, stiffness, and energy absorption capabilities and potential applications in aerospace, automobile, and biomedical industry. To reveal the buckling (global and local) and post-buckling behavior of different lattice morphologies, both experimental and simulation-based studies were carried out. Additionally, a variable-density lattice structure was designed and analyzed to achieve the optimal value of critical buckling load. Latticed columns were fabricated using polyamide 12 material on multi jet fusion 3D printer. The results exhibited that the buckling in lattice columns depends on the distribution of mass, second moment of inertia I, diameter and position of vertical beams, number of horizontal or inclined beams, and location and angle of the beams that support the vertical beams. The number of horizontal and inclined beams and their thickness has an inverse relation with buckling; however, this trend changes after approaching a critical point. It is revealed that vertical beams are more crucial for buckling case, when compared with horizontal or inclined beams; however, material distribution in inclined or horizontal orientation is also critical because they provide support to vertical beams to behave as a single body to bear the buckling load. The results also revealed that the critical buckling load could be increased by designing variable density cellular columns in which the beams at the outer edges of the column are thicker compared with inner beams. However, post-buckling behavior of variable density structures is brittle and local when compared with uniform density lattice structures.

A pilot study applying digital radiography for estimating ratio of supported single-root surface area.

BACKGROUND: The prognosis of a tooth with periodontitis is affected by the amount of supporting bone. A key factor in retaining a tooth is the ratio of supported root surface. Currently, root surfaces cannot be accurately measured using conventional dental radiographs, which only measure the length of bone support on proximal surfaces. METHODS: Eight extracted, single-rooted teeth were 3-dimensionally digitized using a contact technique for true surface area measurements. Root length, projection area, and pixel values were then measured on digital radiographs. The accuracy of the ratio estimation of supported surface area from linear, area, and pixel values was calculated and compared. RESULTS: The mean error from linear estimation was 7.9%; the mean error from area estimation was 1.0%; and the mean error from pixel value estimation was 1.3%. One-way analysis of variance (ANOVA) showed significant differences in all estimations while Scheffé's analysis further revealed significant differences only in the linear estimation. CONCLUSIONS: A three-dimensional digitizing device could be used as a non-destructive method of measuring root surface area. The ratio of supported single-root surface area could be estimated with high accuracy from the projected area data acquired on the digital dental radiographs. The thickness data as reflected from the pixel values in the digital images did not improve the estimation accuracy. Estimations using only length data yielded significantly less accuracy. Digital dental x-ray images provide the potential for estimating the ratio of supported root surface efficiently.

Calculation of simplified single-root surface area from simulated X-ray projection.

BACKGROUND: The prognosis of a tooth affected by periodontitis might depend on the amount of bone remaining around the root surface. The surface area of a single tooth root relates to a simulated x-ray projection. METHODS: The aim of the study was to determine root surface area from radiographs. Two methods were used. In the first, cross-sections of a single-tooth root were simulated using ellipses with different eccentricities. Projection data from 90 directions at 1 degrees intervals were obtained, which were then used to estimate circumferences that were then compared with the known circumference. In the second model, circumference was estimated from projection data derived from the projection of an ellipse with the central ray parallel to the long axis. The estimated circumference was compared with possible circumferences resulting from this projection data. RESULTS: In the first model, all estimated circumferences are less than the true circumferences. The largest error in each case decreased rapidly as the eccentricity of the simulated ellipse decreased. Less than 6% of the largest errors were found when the eccentricity is 0.83. In the second model, the estimation should be within less than 2% of error when the asymmetry factor is less than 0.6. CONCLUSIONS: The circumference of an elliptical object can be approximated from the projection data of this ellipse. Therefore, the surface area of a single tooth root may be estimated with clinically useful accuracy from the projection data.

Accuracy of supported root ratio estimation from projected length and area using digital radiographs.

BACKGROUND: The purpose of this study was to evaluate the accuracy of supported single-root surface ratio estimated from the length and projected area of the tooth, using digital dental radiographs. METHODS: Eight extracted, single-root teeth were three-dimensionally digitized using a contact technique for surface area measurement. The data were then processed using engineering application software and length, projection area, and true surface area of the root at a designated length were obtained. Based on these three measurements, the accuracy of the supported surface area ratio measurement at different lengths of the root was evaluated. RESULTS: The largest mean errors from linear and area estimation were 9.58% and -1.16%, respectively. The 95% confidence intervals were all positive, indicating that linear measurements overestimated supported ratio. T tests showed that linear estimations resulted in significant differences in all eight teeth and area estimations in five teeth. When analyzing the supported ratio of the alveolar bone receding from the cemento-enamel junction (CEJ) toward the apex of the root at each mm, linear estimation showed significant differences down to 8 mm, while area estimation showed significant differences only up to 2 mm. CONCLUSIONS: The results of this study indicate that a reliable estimate of the ratio of root surface area supported by alveolar bone cannot be determined from linear or area data. However, when the marginal bone destruction exceeds 2 mm from the CEJ, area estimation does not show a significant difference in the supported region. As demonstrated in this study, root surface ratio estimation function could be an advantage of digital dental x-ray systems in which projected root area is readily observed.