Biotinylated Photopolymers for 3D-Printed Unibody Lab-on-a-Chip Optical Platforms.

The present work reports the first demonstration of straightforward fabrication of monolithic unibody lab-on-a-chip (ULOCs) integrating bioactive micrometric 3D scaffolds by means of multimaterial stereolithography (SL). To this end, a novel biotin-conjugated photopolymer is successfully synthesized and optimally formulated to achieve high-performance SL-printing resolution, as demonstrated by the SL-fabrication of biotinylated structures smaller than 100 µm. By optimizing a multimaterial single-run SL-based 3D-printing process, such biotinylated microstructures are incorporated within perfusion microchambers whose excellent optical transparency enables real-time optical microscopy analyses. Standard biotin-binding assays confirm the existence of biotin-heads on the surfaces of the embedded 3D microstructures and allow to demonstrate that the biofunctionality of biotin is not altered during the SL-printing, thus making it exploitable for further conjugation with other biomolecules. As a step forward, an in-line optical detection system is designed, prototyped via SL-printing and serially connected to the perfusion microchambers through customized world-to-chip connectors. Such detection system is successfully employed to optically analyze the solution flowing out of the microchambers, thus enabling indirect quantification of the concentration of target interacting biomolecules. The successful application of this novel biofunctional photopolymer as SL-material enables to greatly extend the versatility of SL to directly fabricate ULOCs with intrinsic biofunctionality.

PLA Feedstock Filled with Spent Coffee Grounds for New Product Applications with Large-Format Material Extrusion Additive Manufacturing.

Food waste and loss generate significant waste such as spent coffee grounds (SCGs) from coffee consumption. These byproducts can be valorized by following circular economy and bioeconomy principles, e.g., using SCGs in polymer-based composites for 3D printing. Although desktop-size material extrusion additive manufacturing is increasingly adopted for biomass-polymer-based composites, the potential of large-format direct extrusion 3D printing systems remains unexplored. This work investigated the thermal, rheological, and mechanical properties of PLA/SCG composites for applications with a large-format pellet extrusion 3D printer. The formulations exhibit minimal degradation at typical 3D printing temperatures of PLA, i.e., ∼190 °C, and limited effects on crystallinity by increasing the SCG weight percentage. The decrease in viscosity due to SCGs improves the printability and layer adhesion, as confirmed by the tensile test results, such as higher ultimate tensile strength and elongation at break values compared to those of the state-of-the-art values. Using pellet feedstocks contributes to limiting the effects of thermomechanical degradation by reducing raw material processing, i.e., avoiding filament extrusion. Using PLA/SCGs formulations was demonstrated through 3D printed complex parts with nonplanar slicing techniques, including a large-scale furniture product, validating large-format pellet extrusion 3D printers for scaling up the use of biomass-filled polymers.

Thermally Conductive and Electrically Insulating Polymer-Based Composites Heat Sinks Fabricated by Fusion Deposition Modeling.

This study explores the potential of novel boron nitride (BN) microplatelet composites with combined thermal conduction and electrical insulation properties. These composites are manufactured through Fusion Deposition Modeling (FDM), and their application for thermal management in electronic devices is demonstrated. The primary focus of this work is, therefore, the investigation of the thermoplastic composite properties to show the 3D printing of lightweight polymeric heat sinks with remarkable thermal performance. By comparing various microfillers, including BN and MgO particles, their effects on material properties and alignment within the polymer matrix during filament fabrication and FDM processing are analyzed. The characterization includes the evaluation of morphology, thermal conductivity, and mechanical and electrical properties. Particularly, a composite with 32 wt% of BN microplatelets shows an in-plane thermal conductivity of 1.97 W m-1 K-1, offering electrical insulation and excellent printability. To assess practical applications, lightweight pin fin heat sinks using these composites are designed and 3D printed. Their thermal performance is evaluated via thermography under different heating conditions. The findings are very promising for an efficient and cost-effective fabrication of thermal devices, which can be obtained through extrusion-based Additive Manufacturing (AM), such as FDM, and exploited as enhanced thermal management solutions in electronic devices.

A new perfluoropolyether-based hydrophobic and chemically resistant photoresist structured by two-photon polymerization.

Two-photon polymerization technology has been used to fabricate submicrometer three-dimensional (3D) structures using a new polyfunctional perfluoropolyether-based resist, which is a polymer intrinsically hydrophobic and chemically resistant. The fluorinated resist was designed and synthesized in this work and successfully employed to fabricate woodpile structures in various experimental conditions. This is the first demonstration of the capability to fabricate hydrophobic and chemically resistant 3D structures with submicrometer resolution and arbitrary geometry.

Unveiling the Hidden Properties of Tomato Peels: Cutin Ester Derivatives as Bio-Based Plasticizers for Polylactic Acid.

Polylactic acid (PLA) is one of the most important biopolymers employed on the market due to its good mechanical strength and barrier properties. On the other hand, this material presents a rather low flexibility, limiting its employment. The valorization of bio-based agro-food waste for the modification of bioplastics is a highly appealing approach for the replacement of petrol-based materials. The aim of this work is to employ cutin fatty acids derived from a biopolymer (i.e., cutin), present in waste tomato peels and its bio-based derivatives as new plasticizers to enhance PLA flexibility. In particular, pure 10,16-dihydroxy hexadecanoic acid was extracted and isolated from tomato peels and then functionalized to give the desired compounds. All the molecules developed in this study were characterized by NMR and ESI-MS. Blends at different concentrations (10, 20, 30, and 40% w/w) the flexibility (Tg measurements with differential scanning calorimetry-DSC) of the final material. Furthermore, the physical behavior of two blends obtained by mechanical mixing of PLA and 16-methoxy,16-oxohexadecane-1,7-diyl diacetate was investigated through thermal and tensile tests. The data collected by DSC show a lowering in the Tg of all the blends of PLA with functionalized fatty acids, in comparison with pure PLA. Lastly, the tensile tests highlighted how PLA blended with 16-methoxy,16-oxohexadecane-1,7-diyl diacetate (20% w/w) can efficiently enhance its flexibility.

Novel 3D printing method to reinforce implant-supported denture fiberglass as material for implant prosthesis: A pilot study.

OBJECTIVES: Despite a large amount of materials and methods to make an implant-supported denture, nowadays there is no gold standard. Every solution has pros and cons that guide the clinician and the technician to choose the best solution for a single case. The aim of this study was to evaluate the mechanical characteristics of the fiber-reinforced composite superstructure made by using a novel three-dimensional (3D) printing technology able to create a reinforcing structure patient-specific, more reliable, structurally optimized, and faster than conventional methods. MATERIALS AND METHODS: To evaluate mechanical performances of 3D-printed fiberglass, mechanical characterization of 3D-printed material was performed. Before proceeding with the realization of the final prosthesis, five specimens were created on which the tensile test and volumetric fiber content measurement were performed. Then denture reinforcement 3D printing process began. Initially, the robot prints layers of fiber. Finally, the obtained 3D-printed reinforcement structure was finalized in the lab. RESULTS: The prosthesis obtained through this process was lighter than a traditional prosthesis, there was a greater chemical adhesion between resin and 3D-printed reinforcement structure and a better result was obtained from an esthetic point of view. CONCLUSIONS: The outcomes we obtained endorse its performance both mechanical and esthetic. The entire process is automatic and does not require human operation thanks to specific software programming.

Metallization of Recycled Glass Fiber-Reinforced Polymers Processed by UV-Assisted 3D Printing.

An ever-growing amount of composite waste will be generated in the upcoming years. New circular strategies based on 3D printing technologies are emerging as potential solutions although 3D-printed products made of recycled composites may require post-processing. Metallization represents a viable way to foster their exploitation for new applications. This paper shows the use of physical vapor deposition sputtering for the metallization of recycled glass fiber-reinforced polymers processed by UV-assisted 3D printing. Different batches of 3D-printed samples were produced, post-processed, and coated with a chromium metallization layer to compare the results before and after the metallization process and to evaluate the quality of the finishing from a qualitative and quantitative point of view. The analysis was conducted by measuring the surface gloss and roughness, analyzing the coating morphology and thickness through the Scanning Electron Microscopy (SEM) micrographs of the cross-sections, and assessing its adhesion with cross-cut tests. The metallization was successfully performed on the different 3D-printed samples, achieving a good homogeneity of the coating surface. Despite the influence of the staircase effect, these results may foster the investigation of new fields of application, as well as the use of different polymer-based composites from end-of-life products, i.e., carbon fiber-reinforced polymers.

High-fidelity solvent-resistant replica molding of hydrophobic polymer surfaces produced by femtosecond laser nanofabrication.

We demonstrate that hydrophobic areas formed by femtosecond laser irradiation on poly(methyl methacrylate) (PMMA) and polystyrene (PS) polymer substrates can be faithfully replicated on samples of the same material via a solvent-resistant perfluoropolyether (PFPE) elastomer mold. The replicated PMMA and PS samples show nearly identical micro-nanoscale topography and hydrophobic wetting characteristics as the laser-patterned master substrates. This work combines the femtosecond laser capability of spatially tailoring the wettability with a high-resolution parallel replication method, offering the potential for the efficient production of microfluidic devices with selectively tailored flow behavior.

Fluorescence and Fourier-transform infrared spectroscopy for the analysis of iconic Italian design lamps made of polymeric materials.

The preservation of design object collections requires an understanding of their constituent materials which are often polymeric blends. Challenges associated with aging of complex polymers from objects with an unknown physical history may compromise the interpretation of data from analytical techniques, and therefore complicate the assessment of the condition of polymers in indoor museum environments. This study focuses on the analysis of polymeric materials from three well-known Italian design lamps from the 1960s. To assess the degree of chemical modifications in the polymers, non-destructive molecular spectroscopic techniques, Fourier-transform infrared (FTIR) and fluorescence spectroscopy, have been applied directly on the object surfaces using an optical fiber probe and through examination of micro samples. FTIR spectra of the different polymers, polyvinylacetate (PVAc) for the lamps Taraxacum and Fantasma, and both acrylonitrile-butadiene-styrene polymer (ABS) and cellulose acetate (CA) for the lamp Nesso, allowed the detection of ongoing deterioration processes. Fluorescence spectroscopy proved particularly sensitive for the detection of molecular changes in the polymeric objects, as the spectra obtained from the examined lamps differ significantly from those of the unaged reference materials. Differences in fluorescence spectra are also detected between different points on the same object further indicating the presence of different chemical species on the surfaces. With the aid of complementary data from FTIR spectroscopy, an interpretation of the emission spectra of the studied polymeric objects is here proposed, further suggesting that fluorescence spectroscopy may be useful for following the degradation of historical polymeric objects.

Trends in biomedical engineering: focus on Smart Bio-Materials and Drug Delivery.

The present article reviews on different research lines, namely: drug and gene delivery, surface modification/modeling, design of advanced materials (shape memory polymers and biodegradable stents), presently developed at Politecnico di Milano, Italy. For gene delivery, non-viral polycationic-branched polyethylenimine (b-PEI) polyplexes are coated with pectin, an anionic polysaccharide, to enhance the polyplex stability and decrease b-PEI cytotoxicity. Perfluorinated materials, specifically perfluoroether, and perfluoro-polyether fluids are proposed as ultrasound contrast agents and smart agents for drug delivery. Non-fouling, self-assembled PEG-based monolayers are developed on titanium surfaces with the aim of drastically reducing cariogenic bacteria adhesion on dental implants. Femtosecond laser microfabrication is used for selectively and spatially tuning the wettability of polymeric biomaterials and the effects of femtosecond laser ablation on the surface properties of polymethylmethacrylate are studied. Innovative functionally graded Alumina-Ti coatings for wear resistant articulating surfaces are deposited with PLD and characterized by means of a combined experimental and computational approach. Protein adsorption on biomaterials surfaces with an unlike wettability and surface-modification induced by pre-adsorbed proteins are studied by atomistic computer simulations. A study was performed on the fabrication of porous Shape Memory Polymeric structures and on the assessment of their potential application in minimally invasive surgical procedures. A model of magnesium (alloys) degradation, in a finite element framework analysis, and a bottom-up multiscale analysis for modeling the degradation mechanism of PLA matrices was developed, with the aim of providing valuable tools for the design of bioresorbable stents.

Inkjet Printing of a Benzocyclobutene-Based Polymer as a Low-k Material for Electronic Applications.

Polymeric materials with a low dielectric constant are widely used in the electronic industry due to their properties. In particular, polymer adhesives can be used in many applications such as wafer bonding and three-dimensional integration. Benzocyclobutene (BCB) is a very interesting material thanks to its excellent bonding behavior and dielectric properties. Usually, BCB is applied by spin-coating, although this technology does not allow the fabrication of complex patterns. To obtain complex patterns, it is necessary to use a printing technology, such as inkjet printing. However, inkjet printing of BCB-based inks has not yet been investigated. Here, we show the feasibility of printing complex patterns with a BCB-based ink, reaching a resolution of 130 µm. We demonstrate that with a proper dilution, BCB-based inks enter the printability window and drop ejection is achieved without the formation of satellite drops. In addition, we present the conditions in which there is an appearance of the coffee ring effect. Inks that feature a too high interaction with the substrate are more likely to show the coffee ring effect, deteriorating the printing quality. We also observe that it is possible to achieve a better film uniformity by increasing the number of printed layers, due to redissolution of the BCB-based polymer that helps to level possible inhomogeneities. Our work represents the starting point for an in-depth study of BCB-based polymer fabrication using jet printing technologies, as a comparison of the bonding quality obtained with different materials and different technologies could give more information and broaden the perspective regarding this field.

Layer-by-Layer Fabrication of Hydrogel Microsystems for Controlled Drug Delivery From Untethered Microrobots.

Targeted drug delivery from untethered microrobots is a topic of major interest in current biomedical research. The possibility to load smart materials able to administer active principles on remotely in vivo guidable microdevices constitutes one of the most attractive opportunities to overcome the drawbacks of classical untargeted delivery methodologies. Hydrogels, in particular, are ideal candidates as drug-carrying materials due to their biocompatibility, low cost, and ease of manufacturing. On the other hand, these polymers suffer from poor control over release rate and overall released amount. Starting from these premises, the present article demonstrates the possibility to tune the release of hydrogels applied on magnetically steerable microrobots by fabricating microsystems via layer-by-layer self-assembly. By doing this, the diffusion of chemicals from the hydrogel layers to the external environment can be optimized and the phenomenon of burst release can be strongly limited. The microrobotic platforms employed to transport the hydrogel active material are fabricated by employing 3D printing in combination with wet metallization and present a gold layer on their surface to enhance biocompatibility. The maneuverability of microdevices coated with both thin and thick multilayers is investigated, individuating optimized parameters for efficient actuation.

UV-Assisted 3D Printing of Polymer Composites from Thermally and Mechanically Recycled Carbon Fibers.

Despite the growing global interest in 3D printed carbon fiber reinforced polymers, most of the applications are still limited to high-performance sectors due to the low effectiveness-cost ratio of virgin carbon fibers. However, the use of recycled carbon fibers in 3D printing is almost unexplored, especially for thermoset-based composites. This paper aims to demonstrate the feasibility of recycled carbon fibers 3D printing via UV-assisted direct ink writing. Pyrolyzed recycled carbon fibers with a sizing treatment were firstly shredded to be used as a reinforcement of a thermally and photo-curable acrylic resin. UV-differential scanning calorimetry analyses were then performed to define the material crosslinking of the 3D printable ink. Because of the poor UV reactivity of the resin loaded with carbon fibers, a rheology modifier was added to guarantee shape retention after 3D printing. Thanks to a customized 3D printer based on a commercial apparatus, a batch of specimens was successfully 3D printed. According to the tensile tests and Scanning Electron Microscopy analysis, the material shows good mechanical properties and the absence of layer marks related to the 3D printing. These results will, therefore, pave the way for the use of 3D printed recycled carbon fiber reinforced polymers in new fields of application.

Improving cell seeding efficiency through modification of fiber geometry in 3D printed scaffolds.

Cell seeding on 3D scaffolds is a very delicate step in tissue engineering applications, influencing the outcome of the subsequent culture phase, and determining the results of the entire experiment. Thus, it is crucial to maximize its efficiency. To this purpose, a detailed study of the influence of the geometry of the scaffold fibers on dynamic seeding efficiency is presented. 3D printing technology was used to realize polylactic acid porous scaffolds, formed by fibers with a non-circular cross-sectional geometry, named multilobed to highlight the presence of niches and ridges. An oscillating perfusion bioreactor was used to perform bidirectional dynamic seeding of MG63 cells. The fiber shape influences the fluid dynamic parameters of the flow, affecting values of fluid velocity and wall shear stress. The path followed by cells through the scaffold fibers is also affected and results in a larger number of adhered cells in multilobed scaffolds compared to scaffolds with standard pseudo cylindrical fibers. Geometrical and fluid dynamic features can also have an influence on the morphology of adhered cells. The obtained results suggest that the reciprocal influence of geometrical and fluid dynamic features and their combined effect on cell trajectories should be considered to improve the dynamic seeding efficiency when designing scaffold architecture.

Towards nanowriting on plastics: dip-pen nanolithography of acrylamido-functionalized oligonucleotides on polystyrene.

Model high density DNA arrays have been realized by direct deposition with Dip-Pen Nanolithography of acrylamido-functionalized oligonucleotides (23-mer) on spin-coated, flat polystyrene surfaces. A highly specific interaction between the acrylamide end functionality and polystyrene was found. The surface morphology of the model array was studied by atomic force microscopy (AFM). Spots are clearly seen both in topography and demodulation modes. The array withstands the hybridization process with label free, complementary oligonucleotides and the following cleaning procedures. The final AFM characterization showed significant changes especially in demodulation images which may be an indication that molecular recognition between complementary oligos has occurred.

Additive Re-Manufacturing of Mechanically Recycled End-of-Life Glass Fiber-Reinforced Polymers for Value-Added Circular Design.

Despite the large use of composites for industrial applications, their end-of-life management is still an open issue for manufacturing, especially in the wind energy sector. Additive manufacturing technology has been emerging as a solution, enhancing circular economy models, and using recycled composites for glass fiber-reinforced polymers is spreading as a new additive manufacturing trend. Nevertheless, their mechanical properties are still not comparable to pristine materials. The purpose of this paper is to examine the additive re-manufacturing of end-of-life glass fiber composites with mechanical performances that are comparable to virgin glass fiber-reinforced materials. Through a systematic characterization of the recyclate, requirements of the filler for the liquid deposition modeling process were identified. Printability and material surface quality of different formulations were analyzed using a low-cost modified 3D printer. Two hypothetical design concepts were also manufactured to validate the field of application. Furthermore, an understanding of the mechanical behavior was accomplished by means of tensile tests, and the results were compared with a benchmark formulation with virgin glass fibers. Mechanically recycled glass fibers show the capability to substitute pristine fillers, unlocking their use for new fields of application.

Mechanical Reinforcement by Microalgal Biofiller in Novel Thermoplastic Biocompounds from Plasticized Gluten.

The aim of this work was to develop new bioplastic compounds from wheat gluten, biobased plasticizers (glycerol, octanoic acid and 1,4-butanediol), and microalgal biomass as a filler. The effects of the composition on tensile properties, thermal stability, and water sensitivity were investigated. Microalgal biomass was added with the selected quantities: 10, 20, and 30 per hundred parts (php). Mechanical mixing of the components, i.e., gluten, plasticizer, and microalgae, was followed by molding in a hot press. Microlgal filler improved mechanical properties of the plasticized gluten material: in samples plasticized with 1,4-butanediol, 30 php of biomass increased the tensile modulus by nearly one order of magnitude, from 36.5 MPa to 273.1 MPa, and it also increased the tensile strength from 3.3 MPa to 4.9 MPa. The introduction of microalgal biomass slightly increased the surface sensitivity against water: 30 php of biomass reduced the water contact angle from 41° to 22° in samples plasticized with glycerol, but the biomass lowered the overall water absorption kinetics for material with each plasticizer. Microalgal biomass proved therefore to be an interesting sustainable resource with which to develop materials based on gluten, in particular to increase the mechanical properties of the compounds without reducing thermal stability or water resistance.

Additive Manufacturing of Geopolymers Modified with Microalgal Biomass Biofiller from Wastewater Treatment Plants.

This paper deals with the additive manufacturing of metakaolin-based geopolymers and with the use of microalgal biomass from wastewater treatment plants as biofiller in this kind of cementitious material. The study was developed following the evolution stages of the material, which was prepared and printed as a soft paste and then hardened thanks to an inorganic polymerization reaction (geopolymerization). Thus, the characterization techniques adopted encompassed rheometry, mechanical tests performed on the hardened material, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and mercury intrusion porosimetry (MIP). Microalgal biomass addition, evaluated in this study at 1, 3 and 5 php with respect to the powder weight, affected both the properties of the fresh and of the hardened material. Regarding the former aspect, biomass reduced the yield stress of the pastes, improving the ease of the extrusion process, but potentially worsening the ability to build structures in height. When hardened, geopolymers containing microalgae showed mechanical properties comparable to the unfilled material and a microstructure characterized by smaller pores. Finally, a printing test was successfully performed with a larger printer to assess the feasibility of producing large-scale structures. Taking into account these results, this study demonstrates the possibility of using microalgal biomass as biofiller in geopolymers for additive manufacturing.

Surface behavior and molecular recognition in DNA microarrays from N,N-dimethylacrylamide terpolymers with activated esters as linking groups.

A series of terpolymers made of DMA, NAS and MAPS were synthesized by free radical copolymerization and used as functional coatings for the fabrication of glass slide DNA microarrays. The surface properties of coated glass slides were investigated through contact angle measurements, ellipsometry and atomic force microscopy. The terpolymer molecular weight showed a moderate effect on surface tension (gamma(s) = 56-62 mN x m(-1)), but no clear effect on polymeric layer thickness (5-8 nm) and roughness. Hybridization experiments with amine-functionalized oligonucleotides gave the best fluorescence intensity results for microarrays coated with intermediate-molecular-weight terpolymers. Finally, an accelerated ageing test of the microarray in a humidity chamber showed a nice relationship between decay curves of contact angle against water and fluorescence intensity.

UV-Assisted 3D Printing of Glass and Carbon Fiber-Reinforced Dual-Cure Polymer Composites.

Glass (GFR) and carbon fiber-reinforced (CFR) dual-cure polymer composites fabricated by UV-assisted three-dimensional (UV-3D) printing are presented. The resin material combines an acrylic-based photocurable resin with a low temperature (140 °C) thermally-curable resin system based on bisphenol A diglycidyl ether as base component, an aliphatic anhydride (hexahydro-4-methylphthalic anhydride) as hardener and (2,4,6,-tris(dimethylaminomethyl)phenol) as catalyst. A thorough rheological characterization of these formulations allowed us to define their 3D printability window. UV-3D printed macrostructures were successfully demonstrated, giving a clear indication of their potential use in real-life structural applications. Differential scanning calorimetry and dynamic mechanical analysis highlighted the good thermal stability and mechanical properties of the printed parts. In addition, uniaxial tensile tests were used to assess the fiber reinforcing effect on the UV-3D printed objects. Finally, an initial study was conducted on the use of a sizing treatment on carbon fibers to improve the fiber/matrix interfacial adhesion, giving preliminary indications on the potential of this approach to improve the mechanical properties of the 3D printed CFR components.