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Commercial solid freeform fabrication (SFF) systems, which have been developed for fabrication of wax and polymer parts for form and fit and secondary applications, such as moulds for casting, etc., require further improvements for use in direct processing of structural ceramic and metal parts. Defects, both surface as well as internal, are undesirable in SFF processed ceramic and metal parts for structural and functional applications. Process improvements are needed before any SFF technique can successfully be commercialized for structural ceramic and metal processing. Describes process improvements made in new SFF techniques, called fused deposition of ceramics (FDC) and metals (FDMet), for fabrication of structural and functional ceramic and metal parts. They are based on an existing SFF technique, fused deposition modelling (FDM) and use commercial FDM systems. The current state of SFF technology and commercial FDM systems results in parts with several surface and internal defects which, if not eliminated, severely limit the structural properties of ceramic and metal parts thus produced. Describes systematically, in detail, the nature of these defects and their origins. Discusses several novel strategies for elimination of most of these defects. Shows how some of these strategies have successfully been implemented to result in ceramic parts with structural properties comparable to those obtained in conventionally processed ceramics.

Mechanical cues arising from extracellular matrices greatly affect cellular properties, and hence, are of significance in designing biomaterials. In this study, a DNA crosslinked hydrogel was employed to examine cellular responses of spinal cord neurons to substrate compliances. Using DNA as crosslinkers in polymeric hydrogel formation has given rise to a new class of hydrogels with a number of attractive properties (e.g., reversible gelation and controlled crosslinking). Here, it was demonstrated that by varying length of crosslinker, monomer concentration, and level of crosslinking, DNA gel stiffnesses span from approximately 100 Pa to 30 kPa. Assessment of neurite outgrowth on functionalized DNA gels showed that although primary dendrite length is not significantly affected, spinal cord neurons extend more primary dendrites and shorter axons on stiffer gels. Additionally, a greater proportion of neurons have more primary dendrites and shorter axons on stiffer gels. There is a pronounced reduction in focal adhesion kinase (FAK) when neurons are exposed to stiffer substrates, suggesting its involvement in neuronal mechanosensing and neuritogenesis in response to stiffness. These results demonstrate the importance of mechanical aspects of the cell-ECM interactions, and provide guidance for the design of mechanical properties of bio-scaffolds for neural tissue engineering applications.

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Mechanical properties of a polyacrylamide gel with reversible DNA crosslinks are presented. In this system, three DNA strands replace traditional chemical crosslinkers. In contrast to thermoset chemically crosslinked polyacrylamide, the new hydrogel is thermoreversible; crosslink dissociation without the addition of heat is also feasible by introducing a specific removal DNA strand. This hydrogel is characterized by a critical crosslink concentration at which gelation occurs. Below the critical point, a characteristic temperature exists at which a transition in viscosity is observed. Both temperature-dependent viscosity and elastic modulus of the material are functions of crosslink density.

Fused deposition of ceramics (FDC) is a solid freeform fabrication technique based on extrusion of highly loaded polymer systems. The process utilizes particle loaded thermoplastic binder feedstock in the form of a filament. The filament acts as both the piston driving the extrusion and also the feedstock being deposited. Filaments can fail during FDC via buckling, when the extrusion pressure needed is higher than the critical buckling load that the filament can support. Compressive elastic modulus determines the load carrying ability of the filament and the viscosity determines the resistance to extrusion (or extrusion pressure). A methodology for characterizing the compressive mechanical properties of FDC filament feedstocks has been developed. It was found that feedstock materials with a ratio (E/Z a ) greater than a critical value (3610 5 to 5610 5 s -1 ) do not buckle during FDC while those with a ratio less than this range buckle.

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Researchers have constructed a number of DNA-based nanodevices that undergo stepped configuration changes through the application of single-stranded DNA oligomers. Such devices can be incorporated into gel networks to create new classes of active materials with controllable bulk mechanical properties. This concept was demonstrated in a DNA-crosslinked gel, the stiffness of which was modulated through the application of DNA strands. Each crosslink incorporated a single-stranded region to which a DNA strand with a complementary base sequence (called the fuel strand) bound, thereby changing the nanostructure of the gel network. The gel was restored to its initial stiffness through the application of the complement of the fuel strand, which cleared the fuel strand from the crosslink via competitive binding. Stiffness changes in excess of a factor of three were observed. The ability to switch the mechanical properties of these gels without changing temperature, buffer composition, or other environmental conditions, apart from the application of DNA, makes these materials attractive candidates for biotechnology applications.