Design and Manufacturing of High Surface Area 3D‐Printed Media for Moving Bed Bioreactors for Wastewater Treatment

Elliott, Olivia; Gray, Stephanie; McClay, Michael; Nassief, Bakr; Nunnelley, Ann; Vogt, Eric; Ekong, Gladys; Kardel, Kamran; Khoshkhoo, Ali; Proaño, Gabriel; Blersch, David M.; Carrano, Andres L.

doi:10.1111/j.1936-704x.2017.03246.x

Cited by 63 publications

(41 citation statements)

References 28 publications

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“…The specific surface area and topology of the carrier determine the performance and efficiency of the system. Elliott et al designed and tested media carriers with sheet‐network Gyroid topologies. Their results indicate that the 3D‐printed Gyroidal media can withstand the prevalent conditions in moving bed bioreactors and that the NH 3 removal rate of the Gyroidal media is comparable to that of commercially available media.…”

Section: Applicationsmentioning

confidence: 99%

Multifunctional Mechanical Metamaterials Based on Triply Periodic Minimal Surface Lattices

2019

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In nature, cellular materials exhibit enhanced multifunctionalities driven mainly by their sophisticated topologies and length scales. These natural systems have inspired the development and expansion of synthetic architected materials for revolutionary applications. Consequently, both the design and synthesis techniques gained considerable attention and have massively progressed over the last few decades. Such materials with topology-controlled properties are commonly known as "metamaterials." Architected materials with topologies based on triply periodic minimal surfaces (TPMS) which are of particular interest have attracted much attention recently due to their mathematically controlled fascinating topologies and their exhibited physical and mechanical properties. Herein, the design, synthesis, and use of TPMS in the field of metamaterials and metacomposites for several applications are focused upon. The design process to create TPMS-based 3D lattices is summarized and the different manufacturing processes used to fabricate these lattices are highlighted. Herein, the materialtopology-mechanical properties relationship of different TPMS-based lattices that are investigated in the literature is discussed. A further objective is to highlight the applications where TPMS-based lattices or composites can be efficiently used as well as the research areas to be explored. development of macro/micro/nanomechanics-based constitutive models and computational tools that can be used effectively in guiding the design of advanced materials. He is particularly active in using digital design and 3D printing for creating multifunctional architected materials and composites for various applications.

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Section: Applicationsmentioning

confidence: 99%

Multifunctional Mechanical Metamaterials Based on Triply Periodic Minimal Surface Lattices

2019

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“…These studies included, surface roughness measurement and modeling (Boschetto et al, 2013;Turner and Gold, 2015), dimensional accuracy (Ramli et al, 2018), surface roughness and quality (Agarwal et al, 2018;Armillotta, 2006). In contrast, given their high cost and complexity, only a few studies addressed MJ dimensional accuracy and surface roughness (Elliott et al, 2017;Khoshkhoo et al, 2018). Similarly, there has been a lack of extensive evaluation of such parameters for SLA (Campanelli et al, 2007).…”

Section: Discussionmentioning

confidence: 99%

“…In conventional manufacturing technologies, it is known that dimensional accuracy and surface roughness are important properties to be continuously measured and improved for final products, particularly for applications involving small critical features (Elliott et al, 2017;Withell et al, 2011). Hence, there is even a more urgent need for dimensional capability comparison of the available 3DP technologies to guide future users about their limitations and process windows to further facilitate the applicability of these technologies and equipment.…”

Section: Introductionmentioning

confidence: 99%

Dimensional capability of selected 3DP technologies

Mou

Кочкодан

2019

RPJ

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Purpose This paper aims to report on the findings of an investigation to compare three different three-dimensional printing (3DP) or additive manufacturing technologies [i.e. fused deposition modeling (FDM), stereolithography (SLA) and material jetting (MJ)] and four different equipment (FDM, SLA, MJP 2600 and Object 260) in terms of their dimensional process capability (dimensional accuracy and surface roughness). It provides a comprehensive and comparative understanding about the level of attainable dimensional accuracy, repeatability and surface roughness of commonly used 3DP technologies. It is expected that these findings will help other researchers and industrialists in choosing the right technology and equipment for a given 3DP application. Design/methodology/approach A benchmark model of 5 × 5 cm with several common and challenging features, such as around protrusion and hole, flat surface, micro-scale ribs and micro-scale long channels was designed and printed repeatedly using four different equipment of three different 3DP technologies. The dimensional accuracy of the printed models was measured using non-contact digital measurement methods. The surface roughness was evaluated using a digital profilometer. Finally, the surface quality and edge sharpness were evaluated under a reflected light ZEISS microscope with a 50× magnification objective. Findings The results show that FDM technology with the used equipment results in a rough surface and loose dimensional accuracy. The SLA printer produced a smoother surface, but resulted in the distortion of thin features (<1 mm). MJ printers, on the other hand, produced comparable surface roughness and dimensional accuracy. However, ProJet MJP 3600 produced sharper edges when compared to the Objet 260 that produced round edges. Originality/value This paper, for the first time, provides a comprehensive comparison of three different commonly used 3DP technologies in terms of their dimensional capability and surface roughness without farther post-processing. Thus, it offers a reliable guideline for design consideration and printer selection based on the target application.

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“…Tang et al [ 2 ] used stereolithography technology (SLA) to fabricate a semi-suspended spindle-shaped biocarrier with synthetic material (isocyanate and polyhydric alcohols), which demonstrated the effects of shaped microhabitats on biofilm growth and microbial community diversity [ 2 ]. In preliminary work on the topic, Elliott et al [ 27 ] demonstrated the manufacture of 3D-printed gyroid-based biocarriers using material jetting technologies and established the feasibility of implementing such technology for nitrification MBBRs [ 27 ].…”

Section: Introductionmentioning

confidence: 99%

Analysis of very-high surface area 3D-printed media in a moving bed biofilm reactor for wastewater treatment

2020

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Moving Bed Biofilm Reactors (MBBRs) can efficiently treat wastewater by incorporating suspended biocarriers that provide attachment surfaces for active microorganisms. The performance of MBBRs for wastewater treatment is, among other factors, contingent upon the characteristics of the surface area of the biocarriers. Thus, novel biocarrier topology designs can potentially increase MBBR performance in a significant manner. The goal of this work is to assess the performance of 3-D-printed biofilter media biocarriers with varying surface area designs for use in nitrifying MBBRs for wastewater treatment. Mathematical models, rendering, and 3D printing were used to design and fabricate gyroid-shaped biocarriers with a high degree of complexity at three different levels of specific surface area (SSA), generally providing greater specific surface areas than currently available commercial designs. The biocarriers were inoculated with a nitrifying bacteria community, and tested in a series of batch reactors for ammonia conversion to nitrate, in three different experimental configurations: constant fill ratio, constant total surface area, and constant biocarrier media count. Results showed that large and medium SSA gyroid biocarriers delivered the best ammonia conversion performance of all designs, and significantly better than that of a standard commercial design. The percentage of ammonia nitrogen conversion at 8 hours for the best performing biocarrier design was: 99.33% (large SSA gyroid, constant fill ratio), 94.74% (medium SSA gyroid, constant total surface area), and 92.73% (large SSA gyroid, constant biocarrier media count). Additionally, it is shown that the ammonia conversion performance was correlated to the specific surface area of the biocarrier, with the greatest rates of ammonia conversion (99.33%) and nitrate production (2.7 mg/L) for manufactured gyroid biocarriers with a specific surface area greater than 1980.5 m 2 /m 3 . The results suggest that the performance of commercial MBBRs for wastewater treatment can be greatly improved by manipulation of media design through topology optimization.

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Design and Manufacturing of High Surface Area 3D‐Printed Media for Moving Bed Bioreactors for Wastewater Treatment

Cited by 63 publications

References 28 publications

Multifunctional Mechanical Metamaterials Based on Triply Periodic Minimal Surface Lattices

Multifunctional Mechanical Metamaterials Based on Triply Periodic Minimal Surface Lattices

Dimensional capability of selected 3DP technologies

Analysis of very-high surface area 3D-printed media in a moving bed biofilm reactor for wastewater treatment

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