Topology optimization is a powerful digital engineering tool for the development of lightweight products. Nevertheless, the transition of obtained design proposals into manufacturable parts is still a challenging task. In this article, the development of a freeware framework is shown, which uses a hybrid topology optimization algorithm for stiffness and strength combined with manufacturing constraints based on finite spheres and a two-step smoothing algorithm to design manufacturable prototypes with “one click”. The presented workflow is shown in detail on a rocker, which is “one-click”-optimized and manufactured. These parts were experimentally tested using a universal testing machine. The objective of this article was to investigate the performance of “one-click”-optimized parts in comparison with manually redesigned optimized parts and the initial design space. The test results show that the design proposals created while applying the finite-spheres and two-step smoothing are equal to the manual redesigned parts based on the optimization results, proposing that the “one-click”-development can be used for the fast and direct development and fabrication of prototypes.

Stakeholders in the industry are increasingly using digital twins to take advantage of continuous digitization. The widely used methods for transferring partial models of digital twins within various heterogeneous systems rely on standardized, neutral file-based exchange. However, using differently implemented routines in the pre- and postprocessors of the systems engaged during data transmission leads to compatibility problems. Complete information transfer is not guaranteed, although potentially all information is available in the individual exchange file. To utilize the full potential of digital twins, this paper presents a method for directly adapting the content stored in an exchange file to systematically achieve compatibility. In the first step, we define a general structure to specify interrelated, nonconforming objects that are stored in the exchange file. We present five conditions that specify a compatibility problem in the following steps. On this basis, the applicant can solve various exchange problems for the indicated scenario in the third step. After explaining the approach in general terms, we demonstrate its generality by discussing two diverging use cases based on the exchange formats STEP and INP. We implemented the method in software terms, and the implementation indicates that this method can fix compatibility problems in an automated way.

Hierarchical structures are abundant in almost all tissues of the human body. Therefore, it is highly important for tissue engineering approaches to mimic such structures if a gain of function of the new tissue is intended. Here, the hierarchical structures of the so-called enthesis, a gradient tissue located between tendon and bone, were in focus. Bridging the mechanical properties from soft to hard secures a perfect force transmission from the muscle to the skeleton upon locomotion. This study aimed at a novel method of bioprinting to generate gradient biomaterial constructs with a focus on the evaluation of the gradient printing process. First, a numerical approach was used to simulate gradient formation by computational flow as a prerequisite for experimental bioprinting of gradients. Then, hydrogels were printed in a single cartridge printing set-up to transfer the findings to biomedically relevant materials. First, composites of recombinant spider silk hydrogels with fluorapatite rods were used to generate mineralized gradients. Then, fibroblasts were encapsulated in the recombinant spider silk-fluorapatite hydrogels and gradually printed using unloaded spider silk hydrogels as the second component. Thereby, adjustable gradient features were achieved, and multimaterial constructs were generated. The process is suitable for the generation of gradient materials, e.g., for tissue engineering applications such as at the tendon/bone interface.

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