Design of Complexly Graded Structures inside Three-Dimensional Surface Models by Assigning Volumetric Structures

Abstract

An innovative approach for designing complex structures from STL-datasets based on novel software for assigning volumetric data to surface models is reported. The software allows realizing unique complex structures using additive manufacturing technologies. Geometric data as obtained from imaging methods, computer-aided design, or reverse engineering that exist only in the form of surface data are converted into volumetric elements (voxels). Arbitrary machine data can be assigned to each voxel and thereby enable implementing different materials, material morphologies, colors, porosities, etc. within given geometries. The software features an easy-to-use graphical user interface and allows simple implementation of machine data libraries. To highlight the potential of the modular designed software, an extrusion-based process as well as a two-tier additive manufacturing approach for short fibers and binder process are combined to generate three-dimensional components with complex grading on the material and structural level from STL files.

Treatment of Critical-Size Femoral Bone Defects with Chitosan Scaffolds Produced by a Novel Process from Textile Engineering

“…For this purpose, it is necessary to investigate different matrix systems, e.g., based on bone cements, and to study the fiber-matrix interactions in detail. A fundamental design approach, for the realization of such systems combining fiber-based and pasty components, has been laid down by Brünler et al [25].…”

Isotropic and Anisotropic Scaffolds for Tissue Engineering: Collagen, Conventional, and Textile Fabrication Technologies and Properties

“…Yarns are further processed into 1D, 2D, or 3D textiles using textile technologies by weaving [188], weft knitting [189], warp knitting [190], braiding [191], flocking [192], and fiber based additive manufacturing methods [193] (Figure 9). Due to the application of these textile technologies, the textile structures consist of a spatially defined fiber structure.…”

Functionalization of Silk Fibers by PDGF and Bioceramics for Bone Tissue Regeneration

“…During the process, fibers, which are not exposed to TFA serve as support structure and thus allow the realizing of overhangs, undercuts or cavities, similar to powder printing or SLS. The structures provide an interconnected pore network where the pore size is determined by the fiber properties (length and diameter) and can be precisely defined by modeling and simulation using the GeoDict software (Math2Market GmbH, Kaiserslautern, Germany) as shown in Figure 1 and explained in details in [50,51]. For all fiber-based 3D scaffolds (Silk, Silk-HA/β-TCP, Silk-PDGF and Silk-HA/β-TCP-PDGF) the same model was calculated and used for additive manufacturing by FAM.…”