Fabrication and Characterization of Flexible Medical-Grade TPU Filament for Fused Deposition Modeling 3DP Technology

Haryńska, Agnieszka; Gubańska, Iga; Kucińska-Lipka, Justyna; Janik, Helena

doi:10.3390/polym10121304

Cited by 81 publications

(56 citation statements)

References 60 publications

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“…AM offers increased design freedom, lead-time reductions, and the possibility of functional integration, with AM technologies being increasingly adopted and developed by industry, resulting in more varied and affordable processes, accompanied by greater market acceptance and penetration [1][2][3]. In particular, 3D printing has become a viable alternative to conventional manufacturing processes in numerous applications, i.e., in the automobile, aerospace, medical, and construction industries and widely in furniture production [4][5][6][7]. Especially in the aerospace sector, parts previously manufactured by traditional means are being replaced by additively manufactured low-weight polymer components.…”

Section: Introductionmentioning

confidence: 99%

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Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

2020

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This article reports on the investigation of the effects of process parameters and their interactions on as-built part quality and resource-efficiency of the fused filament fabrication 3D printing process. In particular, the influence of five process parameters: infill percentage, layer thickness, printing speed, printing temperature, and surface inclination angle on dimensional accuracy, surface roughness of the built part, energy consumption, and productivity of the process was examined using Taguchi orthogonal array (L50) design of experiment. The experimental results were analyzed using ANOVA and statistical analysis, and the parameters for optimal responses were identified. Regression models were developed to predict different process responses in terms of the five process parameters experimentally examined in this study. It was found that dimensional accuracy is negatively influenced by high values of layer thickness and printing speed, since thick layers of printed material tend to spread out and high printing speeds hinder accurate deposition of the printed material. In addition, the printing temperature, which regulates the viscosity of the used material, plays a significant role and helps to minimize the dimensional error caused by thick layers and high printing speeds, whereas the surface roughness depends very much on surface inclination angle and layer thickness, which together determine the influence of the staircase effect. Energy consumption and productivity are primarily affected by printing speed and layer thickness, due to their high correlation with build time.

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Section: Introductionmentioning

confidence: 99%

“…industries and widely in furniture production [4][5][6][7]. Especially in the aerospace sector, parts previously manufactured by traditional means are being replaced by additively manufactured lowweight polymer components.…”

Section: Introductionmentioning

confidence: 99%

Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

2020

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“…In fact, the incidence of catheter-related bloodstream infection is lower for PU catheters than those made of PVC or PU and so it is the current material of choice in manufacturing of catheters, particularly due to its potential to form sustained release polymers through HME, which has been proven in medical tubing [78]. One study in particular outlines the use of TPU in HME and its potential for use in FDM printing [79]. To conclude, TPU filament is suitable for 3D printing and has potential for creating customised and repeatable products.…”

Section: Thermoplastic Poly(urethane)mentioning

confidence: 99%

Fused Deposition Modelling as a Potential Tool for Antimicrobial Dialysis Catheters Manufacturing: New Trends vs. Conventional Approaches

et al. 2019

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The rising rate of individuals with chronic kidney disease (CKD) and ineffective treatment methods for catheter-associated infections in dialysis patients has led to the need for a novel approach to the manufacturing of catheters. The current process requires moulding, which is time consuming, and coated catheters used currently increase the risk of bacterial resistance, toxicity, and added expense. Three-dimensional (3D) printing has gained a lot of attention in recent years and offers the opportunity to rapidly manufacture catheters, matched to patients through imaging and at a lower cost. Fused deposition modelling (FDM) in particular allows thermoplastic polymers to be printed into the desired devices from a model made using computer aided design (CAD). Limitations to FDM include the small range of thermoplastic polymers that are compatible with this form of printing and the high degradation temperature required for drugs to be extruded with the polymer. Hot-melt extrusion (HME) allows the potential for antimicrobial drugs to be added to the polymer to create catheters with antimicrobial activity, therefore being able to overcome the issue of increased rates of infection. This review will cover the area of dialysis and catheter-related infections, current manufacturing processes of catheters and methods to prevent infection, limitations of current processes of catheter manufacture, future directions into the manufacture of catheters, and how drugs can be incorporated into the polymers to help prevent infection.

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“…Along with PLA, TPU was remarked in the additive manufacturing technology [15]. The TPU applications in the medical field spread from blood vessels, implants, and prosthetics, to scaffolding in tissue engineering, dialysis membranes, or breast implants [16].Furthermore, naturally derived hydroxyapatite (HA) is a bioactive ceramic, with similar chemical and structural properties to the mineral component of the natural bone tissue, and exceptional biocompatibility and osteoconductivity. HA can be synthesized from various renewable resources (e.g.…”

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confidence: 99%

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Novel Synthesis of Core-Shell Biomaterials from Polymeric Filaments with a Bioceramic Coating for Biomedical Applications

et al. 2020

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Bone tissue engineering is constantly in need of new material development with improved biocompatibility or mechanical features closer to those of natural bone. Other important factors are the sustainability, cost, and origin of the natural precursors involved in the technological process. This study focused on two widely used polymers in tissue engineering, namely polylactic acid (PLA) and thermoplastic polyurethane (TPU), as well as bovine-bone-derived hydroxyapatite (HA) for the manufacturing of core-shell structures. In order to embed the ceramic particles on the polymeric filaments surface, the materials were introduced in an electrical oven at various temperatures and exposure times and under various pressing forces. The obtained core-shell structures were characterized in terms of morphology and composition, and a pull-out test was used to demonstrate the particles adhesion on the polymeric filaments structure. Thermal properties (modulated temperature and exposure time) and the pressing force's influence upon HA particles' insertion degree were evaluated. More to the point, the form variation factor and the mass variation led to the optimal technological parameters for the synthesis of core-shell materials for prospect additive manufacturing and regenerative medicine applications.Coatings 2020, 10, 283 2 of 18 importance. Among these, PLA was widely used, mainly due to its biocompatibility with the human organism and the advantageous synthesis alternative from sustainable natural resources (e.g., beet or maize) [14]. Along with PLA, TPU was remarked in the additive manufacturing technology [15]. The TPU applications in the medical field spread from blood vessels, implants, and prosthetics, to scaffolding in tissue engineering, dialysis membranes, or breast implants [16].Furthermore, naturally derived hydroxyapatite (HA) is a bioactive ceramic, with similar chemical and structural properties to the mineral component of the natural bone tissue, and exceptional biocompatibility and osteoconductivity. HA can be synthesized from various renewable resources (e.g. fish, sheep, cattle or bovine bones [17,18] or marine shells [19,20]).Along with the development of new biomaterials, the cost-efficient and highly performant processing techniques for final products manufacturing are also in need of improvement. Additive manufacturing (AM) or 3D printing can be considered 21st century technology due to the possibility to attain patient-customized and adapted products [14]. However, the most widely and accessible used technique in orthopedics is fused deposition modeling (FDM) or fused filler fabrication (FFF) [8,14,21,22], which provide 3D scaffolds with a well-defined design by extruding a digital 3D model from thermoplastic polymeric materials heated to their melting point [22].This study aims to provide a new core-shell material that can be used in the FDM technique, targeted due to its rigorous control of parameters (temperature, bed temperature, feed rate, printing speed, etc.) [23][24][25][26][27].Therefore, thi...

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Fabrication and Characterization of Flexible Medical-Grade TPU Filament for Fused Deposition Modeling 3DP Technology

Cited by 81 publications

References 60 publications

Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

Fused Deposition Modelling as a Potential Tool for Antimicrobial Dialysis Catheters Manufacturing: New Trends vs. Conventional Approaches

Novel Synthesis of Core-Shell Biomaterials from Polymeric Filaments with a Bioceramic Coating for Biomedical Applications

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