Multi-gel casting apparatus for vertical polyacrylamide gels with in-built solution flow system and liquid level detectors.

PAGE is the most widely used technique for the separation and biochemical analysis of biomolecules. The ever growing field of proteomics and genomics necessitates the analysis of many proteins and nucleic acid samples to understand further about the structure and function of cells. Simultaneous analysis of multiple protein samples often requires casting of many PAGE gels. Several variants of multi-gel casting/electrophoresis apparatuses are frequently used in research laboratories. Requirement of supplementary gels to match the growing demand for analyzing additional protein samples sometimes become a cause of concern. Available apparatuses are not amenable to and therefore, not recommended for any modification to accommodate additional gel casting units other than what is prescribed by the manufacturer. A novel apparatus is described here for casting multiple PAGE gels comprising four detachable components that provide enhanced practicability and performance of the apparatus. This newly modified apparatus promises to be a reliable source for making multiple gels in less time without hassle. Synchronized functioning of unique components broaden the possibilities of developing inexpensive, safe, and time-saving multi-gel casting apparatus. This apparatus can be easily fabricated and modified to accommodate desired number of gel casting units. The estimated cost (∼$300) for fabrication of the main apparatus is very competitive and effortless assembly procedure can be completed within ∼30 min.

Biomimetic Porous Ti6Al4V Implants: A Novel Interbody Fusion Cage via Gel-Casting Technique to Promote Spine Fusion.

An interbody fusion cage (Cage) is crucial in spinal decompression and fusion procedures for restoring normal vertebral curvature and rebuilding spinal stability. Currently, these Cages suffer from issues related to mismatched elastic modulus and insufficient bone integration capability. Therefore, a gel-casting technique is utilized to fabricate a biomimetic porous titanium alloy material from Ti6Al4V powder. The biomimetic porous Ti6Al4V is compared with polyetheretherketone (PEEK) and 3D-printed Ti6Al4V materials and their respective Cages. Systematic validation is performed through mechanical testing, in vitro cell, in vivo rabbit bone defect implantation, and ovine anterior cervical discectomy and fusion experiments to evaluate the mechanical and biological performance of the materials. Although all three materials demonstrate good biocompatibility and osseointegration properties, the biomimetic porous Ti6Al4V, with its excellent mechanical properties and a structure closely resembling bone trabecular tissue, exhibited superior bone ingrowth and osseointegration performance. Compared to the PEEK and 3D-printed Ti6Al4V Cages, the biomimetic porous Ti6Al4V Cage outperforms in terms of intervertebral fusion performance, achieving excellent intervertebral fusion without the need for bone grafting, thereby enhancing cervical vertebra stability. This biomimetic porous Ti6Al4V Cage offers cost-effectiveness, presenting significant potential for clinical applications in spinal surgery.

Rare-Earth-Zirconate Porous High-Entropy Ceramics with Unique Pore Structures for Thermal Insulating Applications.

Porous high-entropy ceramics are a new alternative material for thermal insulation. Their better stability and low thermal conductivity are due to lattice distortion and unique pore structures. In this work, rare-earth-zirconate ((La0.25Eu0.25Gd0.25Yb0.25)2(Zr0.75Ce0.25)2O7) porous high-entropy ceramics were fabricated by a tert-butyl alcohol (TBA)-based gel-casting method. The regulation of pore structures was realized through changing different initial solid loadings. The XRD, HRTEM, and SAED results showed that the porous high-entropy ceramics had a single fluorite phase without impurity phases, exhibiting high porosity (67.1-81.5%), relatively high compressive strength (1.02-6.45 MPa) and low thermal conductivity (0.0642-0.1213 W/(m·K)) at room temperature. Porous high-entropy ceramics with 81.5% porosity demonstrated excellent thermal properties, showing a thermal conductivity of 0.0642 W/(m·K) at room temperature and 0.1467 W/(m·K) at 1200 °C. The unique pore structure with a micron size contributed to their excellent thermal insulating performance. The present work provides the prospect that rare-earth-zirconate porous high-entropy ceramics with tailored pore structures are expected to be thermal insulation materials.

Influence of Solid Loading on the Gel-Casting of Porous NiTi Alloys.

Porous NiTi alloys are widely applied in the field of medical implant materials due to their excellent properties. In this paper, porous NiTi alloys were prepared by non-aqueous gel-casting. The influence of solid loading on the process characteristics of slurries and the microstructure and mechanical properties of sintered samples were investigated. The viscosity and the stability of slurry significantly increased with the growth of solid loading, and the slurry had better process characteristics in the solid loading range of 40-52 vol.%. Meanwhile, the porosity and average pore diameter of the sintered NiTi alloys decreased with a rise in the solid loading, while the compressive strength increased. Porous NiTi alloys with porosities of 43.3-48.6%, average pore sizes of 53-145 µm, and compressive strengths of 87-167 MPa were fabricated by gel-casting. These properties meet the requirements of cortical bone. The results suggest that the pore structure and mechanical properties of porous NiTi products produced by gel-casting can be adjusted by controlling the solid loading.

Microstructure and Mechanical Properties of Porous NiTi Alloy Prepared by Integration of Gel-Casting and Microwave Sintering.

Porous NiTi alloys were manufactured by integration of gel-casting and microwave sintering. The effects of sintering temperature on porosity, compressive strength, pore morphology and phase composition of sintered samples were researched. The results show that the porosity and the mean pore diameter of porous NiTi alloys decrease with increasing sintering temperature, whereas the content of the NiTi phase, the elastic modulus and compressive strength of sintered samples increase. When the gel body with the solid loading of 50 vol.% is microwave sintered at 1000 °C for 30 min, porous NiTi alloys are obtained with the porosity of 38.9%, the compressive strength of 254 MPa, elastic modulus of 4 GPa, and predominant phase of NiTi. The results suggest that the method is suitable for rapid preparation of large-size and complex-shape personalized products similar to human bones at a low cost.

A Novel Preparation of Special-Shaped Phosphors-in-Glass by Gel Casting with Isobam for High-Power WLEDs Lighting.

Phosphors-in-glass (PiGs) regarded as a promising phosphor-converter for white light emitting diodes (WLEDs) is being researched widely. However, there are few reports on the effect of changing the shape of PiGs on the color rendering index (CRI) and heat dissipation of WLEDs. In this paper, gel casting with Isobam was first attempted in preparing special-shaped PiGs successfully. It exhibited that 76 wt.% was the optimum solid content based on the rheological properties of slurry and the shrinkage of green bodies. The sintering rate should be kept at a low speed and glass transition temperature (Tg) of glass powders must be higher than sublimation temperatures (Ts) of APS and Isobam. The CRI of PiGs was increased by about 27% after changing the shape of PiGs from cylinder to dome. Most importantly, operating temperature also reduced effectively the increase of the surface area of PiGs. Therefore, changing the shape of PiGs by gel casting with Isobam is a creative way for high-power WLEDs lighting.

A Finite Element Analysis for Improvement of Shaping Process of Complex-Shaped Large-Size Silicon Carbide Mirrors.

In the gel-casting process, the proper selection of technological parameters is crucial for the final quality of a green body. In this work, the finite element method is used to investigate the mold characteristics in the gel-casting process, and the typical flow behaviors under different conditions are presented. Based on the distribution characteristics of temperature, pressure and flow field of gel polymer, the simulated results provide some possible reasons for the generation mechanisms of defects. Then, a series of simulations were performed to investigate the effect of process parameters on the molding quality of green gel-cast bodies. The results show that the decreasing loading speed can effectively reduce the number of defects and improve the molding quality. In addition, this paper presents a new technique by applying the exhaust hole to decrease the number of defects and, hence, improve structural integrity. The influence of the loading speed on the mold characteristics is well understood for the gating system with an exhaust hole, which suggests to us appropriate parameters for optimizing the molding design. This work provides a theoretical basis to explicate the generating mechanism of defects involved in the gel-casting process and acquires an optimized technique to produce a silicon carbide green body.

Effect of Chopped ZrO2 Fiber Content on the Microstructure and Properties of CaO-Based Integral Ceramic Mold.

A chopped ZrO2 fiber (ZrO2(f)) reinforced CaO-based integral ceramic mold was successfully fabricated by stereolithography (SLA) and tert-butyl alcohol (TBA)-based gel-casting, and the effect of chopped ZrO2(f) content on properties of the ceramic mold was investigated. The results show that the ZrO2(f) content had a significant effect on the viscosity of CaO-based ceramic slurry, which directly affects the filling ability of slurry in complex structures of the integral mold. The tiny structures of the ceramic mold cannot be filled completely with a ZrO2(f) content exceeding 3 vol %. The sample fabricated with 3 vol % fiber content showed a harmonious microstructure and exhibited an excellent comprehensive performance with 25 °C bending strength of 22.88 MPa, an 1200 °C bending strength of 15.74 MPa, a 1200 °C deflection of 0.86 mm, and a sintering shrinkage of 0.40%, which can meet the requirements of casting very well.

Modeling the Physical Properties of Gamma Alumina Catalyst Carrier Based on an Artificial Neural Network.

Porous γ-alumina is widely used as a catalyst carrier due to its chemical properties. These properties are strongly correlated with the physical properties of the material, such as porosity, density, shrinkage, and surface area. This study presents a technique that is less time consuming than other techniques to predict the values of the above-mentioned physical properties of porous γ-alumina via an artificial neural network (ANN) numerical model. The experimental data that was implemented was determined based on 30 samples that varied in terms of sintering temperature, yeast concentration, and socking time. Of the 30 experimental samples, 25 samples were used for training purposes, while the other five samples were used for the execution of the experimental procedure. The results showed that the prediction and experimental data were in good agreement, and it was concluded that the proposed model is proficient at providing high accuracy estimation data derived from any complex analytical equation.

Preparation of high strength zirconia by epoxy gel-casting using hydantion epoxy resin as a gelling agent.

In this paper, a water soluble hydantion epoxy resin (ER) was employed to prepare zirconia green bodies with high mechanical strength via epoxy gel-casting (EGC) for dental applications. The rheological properties and gelation behaviors of the suspensions, and the microstructure and mechanical strength of zirconia were systematically studied. The results revealed that solid loadings of up to 52.0 vol% could be achieved with the addition of 0.8 wt% dispersant. When the concentration of ER in the 52.0 vol% suspensions increased from 10.0 to 25.0 wt%, the mechanical strength of the resulting green bodies was enhanced from 40.96 ±â€¯5.20 to 51.22 ±â€¯12.01 MPa. A rough sketch of a pre-sintered zirconia crown was soft-machined from the green body consolidated from a 52.0 vol% suspension containing 10.0 wt% ER. The sintered body had a high mechanical strength of 942.77 ±â€¯95.61 MPa.

Glass-Ceramic Foams from 'Weak Alkali Activation' and Gel-Casting of Waste Glass/Fly Ash Mixtures.

A 'weak alkali activation' was applied to aqueous suspensions based on soda lime glass and coal fly ash. Unlike in actual geopolymers, an extensive formation of zeolite-like gels was not expected, due to the low molarity of the alkali activator (NaOH) used. In any case, the suspension underwent gelation and presented a marked pseudoplastic behavior. A significant foaming could be achieved by air incorporation, in turn resulting from intensive mechanical stirring (with the help of a surfactant), before complete hardening. Dried foams were later subjected to heat treatment at 700⁻900 °C. The interactions between glass and fly ash, upon firing, determined the formation of new crystal phases, particularly nepheline (sodium alumino⁻silicate), with remarkable crushing strength (~6 MPa, with a porosity of about 70%). The fired materials, finally, demonstrated a successful stabilization of pollutants from fly ash and a low thermal conductivity that could be exploited for building applications.

Evaluation of the sintering temperature on the mechanical behavior of ß-tricalcium phosphate/calcium silicate scaffolds obtained by gelcasting method.

Scaffolds have been studied during the last decades as an alternative method to repair tissues. They are porous structures that act as a substrate for cellular growth, proliferation and differentiation. In this study, scaffolds of ß-tricalcium phosphate with calcium silicate fibers were prepared by gel casting method in order to be characterized and validated as a better choice for bone tissue treatment. Gel-casting led to scaffolds with high porosity (84%) and pores sizes varying from 160 to 500 µm, which is an important factor for the neovascularization of the growing tissue. Biocompatible and bioactive calcium silicate fibers, which can be successfully produced by molten salt method, were added into the scaffolds as a manner to improve its mechanical resistance and bioactivity. The addition of 5 wt% of calcium silicate fibers associated with a higher sintering temperature (1300 °C) increased by 64.6% the compressive strength of the scaffold and it has also led to the formation of a dense and uniform apatite layer after biomineralization assessment.

Fabrication of Lanthanum Strontium Manganite Ceramics via Agar Gel Casting and Solid State Sintering.

Fabricating lanthanum strontium manganite (LSM) ceramics with certain shapes is important for the design and construction of high-temperature energy conversion and storage devices. Here, we describe a low-cost and environmentally friendly method for fabricating LSM ceramics via agar gel casting and high temperature sintering. This new approach uses temperature tuning to fabricate LSM gel bodies, not only by manufacturing in the secondary process but also by remolding and recycling during the gel casting process. The effect of the sintering temperature on the properties of LSM ceramics was investigated as well. As a result, the porosity and compressive strength of LSM ceramics sintered at 1000 °C are ~60% and 5.6 MPa, respectively. When the sintering temperature increases to 1200 °C, the porosity decreases to ~28%, whereas the compressive strength increases to 25 MPa, which is able to meet the requirement of cathode-supported SOFCs (solid oxide fuel cells).

Isoelectric Focusing in Agarose Gel for Detection of Oligoclonal Bands in Cerebrospinal and Other Biological Fluids.

Isoelectric focusing (IEF) coupled with immunodetection (immunofixation or immunoblotting) has become the leading technique for the detection and study of oligoclonal bands (OCBs) in cerebrospinal fluid (CSF) and also is increasingly used in other body fluids such as the tear and serum. Limited commercial availability of precast agarose IEF gels for research and a need for customization prompted reporting a detailed general protocol for the preparation and casting of agarose IEF gel along with sample, control, and isoelectric point marker preparation and carrying out the focusing itself for CSF OCBs. However, the method is readily adaptable to the use of other body fluid specimens and, possibly, research specimens such as culture fluids as well.

Simultaneous enhancement of elasticity and strength of Al2O3-based ceramics body from cellulose nanocrystals via gel-casting process.

A green gel-casting method was developed by the combination of rod-like cellulose nanocrystals (CNC) and low toxicity monomer N, N-dimethylacrylamide (DMAA), which was proved to be a promising substitute of traditional neurotoxin monomer acrylamide (AM). The hydrophilic nature and homogeneous dispersion of CNC in aqueous suspension ensured the essential compatibility with the hydrosoluble polymerization system, and therefore provided remarkable mechanical enhancement of green body. The bending strength of the green body was highly increased by 68% with the introduction of 0.9 wt‰ CNC. Meanwhile, the fabricated green body exhibited significant improvement in flexibility and elasticity, with the unique bendable and recovery performances after drying treatment at room temperature for 1h. The computer stimulation by the COMSOL Multiphysics confirmed the special mechanical enhancement effect induced by the presence of highly-crystalline and rigid CNC.

Extension of the 'Inorganic Gel Casting' Process to the Manufacturing of Boro-Alumino-Silicate Glass Foams.

A new technique for the production of glass foams, based on alkali activation and gel casting, previously applied to soda-lime glass, was successfully extended to boro-alumino-silicate glass, recovered from the recycling of pharmaceutical vials. A weak alkali activation (2.5 M NaOH or NaOH/KOH aqueous solutions) of fine glass powders (below 70 µm) allowed for the obtainment of well-dispersed concentrated aqueous suspensions, undergoing gelation by treatment at low temperature (75 °C). Unlike soda-lime glass, the progressive hardening could not be attributed to the formation of calcium-rich silicate hydrates. The gelation was provided considering the chemical formulation of pharmaceutical glass (CaO-free) to the formation of hydrated sodium alumino-silicate (N-A-S-H) gel. An extensive direct foaming was achieved by vigorous mechanical stirring of partially gelified suspensions, comprising also a surfactant. A sintering treatment at 700 °C, was finally applied to stabilize the cellular structures.

Bioactive Glass-Ceramic Foam Scaffolds from 'Inorganic Gel Casting' and Sinter-Crystallization.

Highly porous bioactive glass-ceramic scaffolds were effectively fabricated by an inorganic gel casting technique, based on alkali activation and gelification, followed by viscous flow sintering. Glass powders, already known to yield a bioactive sintered glass-ceramic (CEL2) were dispersed in an alkaline solution, with partial dissolution of glass powders. The obtained glass suspensions underwent progressive hardening, by curing at low temperature (40 °C), owing to the formation of a C-S-H (calcium silicate hydrate) gel. As successful direct foaming was achieved by vigorous mechanical stirring of gelified suspensions, comprising also a surfactant. The developed cellular structures were later heat-treated at 900-1000 °C, to form CEL2 glass-ceramic foams, featuring an abundant total porosity (from 60% to 80%) and well-interconnected macro- and micro-sized cells. The developed foams possessed a compressive strength from 2.5 to 5 MPa, which is in the range of human trabecular bone strength. Therefore, CEL2 glass-ceramics can be proposed for bone substitutions.

Fabrication and Characterization of Porous MgAl2O4 Ceramics via a Novel Aqueous Gel-Casting Process.

A novel and aqueous gel-casting process has been successfully developed to fabricate porous MgAl2O4 ceramics by using hydratable alumina and MgO powders as raw materials and deionized water as hydration agent. The effects of different amounts of deionized water on the hydration properties, apparent porosity, bulk density, microstructure, pore size distribution and compressive strength of the samples were investigated. The results indicated that the porosity and the microstructure of porous MgAl2O4 ceramics were governed by the amounts of deionized water added. The porous structure was formed by the liberation of physisorbed water and the decomposition of hydration products such as bayerite, brucite and boehmite. After determining the addition amounts of deionized water, the fabricated porous MgAl2O4 ceramics had a high apparent porosity (52.5-65.8%), a small average pore size structure (around 1-3 µm) and a relatively high compressive strength (12-28 MPa). The novel aqueous gel-casting process with easy access is expected to be a promising candidate for the preparation of Al2O3-based porous ceramics.

Bioactive Glass-Ceramic Scaffolds from Novel 'Inorganic Gel Casting' and Sinter-Crystallization.

Highly porous wollastonite-diopside glass-ceramics have been successfully obtained by a new gel-casting technique. The gelation of an aqueous slurry of glass powders was not achieved according to the polymerization of an organic monomer, but as the result of alkali activation. The alkali activation of a Ca-Mg silicate glass (with a composition close to 50 mol % wollastonite-50 mol % diopside, with minor amounts of Na2O and P2O5) allowed for the obtainment of well-dispersed concentrated suspensions, undergoing progressive hardening by curing at low temperature (40 °C), owing to the formation of a C-S-H (calcium silicate hydrate) gel. An extensive direct foaming was achieved by vigorous mechanical stirring of partially gelified suspensions, comprising also a surfactant. The open-celled structure resulting from mechanical foaming could be 'frozen' by the subsequent sintering treatment, at 900-1000 °C, causing substantial crystallization. A total porosity exceeding 80%, comprising both well-interconnected macro-pores and micro-pores on cell walls, was accompanied by an excellent compressive strength, even above 5 MPa.

Porous bodies of hydroxyapatite produced by a combination of the gel-casting and polymer sponge methods.

A combination of gel-casting and polymeric foam infiltration methods is used in this study to prepare porous bodies of hydroxyapatite (HA), to provide a better control over the microstructures of samples. These scaffolds were prepared by impregnating a body of porous polyurethane foam with slurry containing HA powder, and using a percentage of solids between 40% and 50% w/v, and three different types of monomers to provide a better performance. X-Ray Diffraction (XRD), and Fourier Transformed Infrared (FTIR) and Scanning Electron Microscopy (SEM) were employed to evaluate both the powder hydroxyapatite and the scaffolds obtained. In addition, porosity and interconnectivity measurements were taken in accordance with the international norm. Bioactivity was checked using immersion tests in Simulated Body Fluids (SBF). After the sintering process of the porous bodies, the XRD results showed peaks characteristic of a pure and crystalline HA (JCPDS 9-432) as a single phase. SEM images indicate open and interconnected pores inside the material, with pore sizes between 50 and 600 µm. Also, SEM images demonstrate the relatively good bioactivity of the HA scaffolds after immersion in SBF. All results for the porous HA bodies suggest that these materials have great potential for use in tissue engineering.