The potentials of additive manufacturing for mass production of electrochemical energy systems

Additive manufacturing has established itself as a popular and powerful tool in electrochemistry research and development. In this short review, we focus on the latest results in both 3D printing and electrochemistry communities that could potentially benefit manufacturing in the electrochemical industry. We provide insights from recent and relevant research works and conclude that the likely scenario in the industry is the deployment of a combination of subtractive and additive technologies in order to manufacture high quality and cost-effective electrochemical reactors within reasonable timeframes.     

3D printing for aqueous and non-aqueous redox flow batteries

Additive manufacturing technologies, generally grouped under the name of 3D printing, are experiencing an explosion of interest during the last few years. The possibility of fast prototyping enabled by 3D printing has been recognized as a crucial booster for device fabrication and general scientific advancements. In this review, attention is focused on the latest developments in the field of redox flow batteries which are, similar to other energy related devices, characterized by the recent adoption of 3D printing methods for the fabrication of key components. Whether simply to investigate flow phenomena, test new designs or fabricate final-product components with custom features, the use of 3D printing can critically drive this field of research towards better performing energy-storage systems. The latest and most representative examples of redox flow battery studies will be discussed, categorized in relation to the electrolyte used and whether the devices are employed in aqueous or non-aqueous applications.     

Pandemic-Driven Development of a Medical-Grade,Economic and Decentralized Applicable Polyolefin Filament for Additive Fused Filament Fabrication

A polyolefin with certified biocompatibility according to USP class VI was used by our group as feedstock for filament-based 3D printing to meet the highest medical standards in order to print personal protective equipment for our university hospital during the ongoing pandemic. Besides the chemical resistance and durability, as well as the ability to withstand steam sterilization, this polypropylene (PP) copolymer is characterized by its high purity, as achieved by highly efficient and selective catalytic polymerization. As the PP copolymer is suited to be printed with all common printers in fused filament fabrication (FFF), it offers an eco-friendly cost–benefit ratio, even for large-scale production. In addition, a digital workflow was established focusing on common desktop FFF printers in the medical sector. It comprises the simulation-based optimization of personalized print objects, considering the inherent material properties such as warping tendency, through to validation of the process chain by 3D scanning, sterilization, and biocompatibility analysis of the printed part. This combination of digital data processing and 3D printing with a sustainable and medically certified material showed great promise in establishing decentralized additive manufacturing in everyday hospital life to meet peaks in demand, supply bottlenecks, and enhanced personalized patient treatment.     

Polycaprolactone solution–based ink for designing microfluidic channels on paper via 3D printing platform for biosensing application

This work reports a novel fabrication technique for development of channels on paper‐based microfluidic devices using the syringe module of a 3D printing syringe–based system. In this study, printing using polycaprolactone (PCL)‐based ink (Mw 70 000‐90 000) was employed for the generation of functional hydrophobic barriers on Whatman qualitative filter paper grade 1 (approximate thickness of 180 μm and pore diameter of 11 μm), which would effectively channelize fluid flow to multiple assay zones dedicated for different analyte detection on a microfluidic paper‐based analytical device (μPAD). The standardization studies reveal that a functional hydrophilic channel for sample conduction fabricated using the reported technique can be as narrow as 460.7 ± 20 μm and a functional hydrophobic barrier can be of any width with a lower limit of about 982.2 ± 142.75 μm when a minimum number of two layers of the ink is extruded onto paper. A comparison with the hydrodynamic model established for writing with ink is used to explain the width of the line printed by this system. A fluid flow analysis through a single channel system was also carried out to establish its conformity with the Washburn model, which governs the fluid flow in two‐dimensional μPAD. The presented fabrication technique proves to be a robust strategy that effectively taps the advantages of this 3D printing technique in the production of μPADs with enhanced speed and reproducibility.     

The effect of 3D printing on the morphological and mechanical properties of polycaprolactone filament and scaffold

Three‐dimensional (3D) printing becomes an attractive technique to fabricate tissue engineering scaffolds through its high control on fabrication and repeatability using the printing parameters. This technique can be combined by the finite element method (FEM), and tissue‐specific scaffolds with desirable morphological and mechanical properties can be designed and manufactured. In this study, the influential 3D printing parameters on the morphological and mechanical properties of polycaprolactone (PCL) filament and scaffold were studied experimentally and numerically. First, the effects of printing parameters and process on the properties of extruded PCL filament were investigated. Then, using FEM, the effects of filament specifications on the overall characteristics of the scaffold were evaluated. Results showed that both the printing process in terms of resting time and remaining time and the printing parameters like pressure, printing speed, and printing path length have influenced the filament properties. In addition, both the filament diameter and elastic modulus had significant effects on the properties of scaffold especially, a 20% increase in the filament diameter caused the scaffold compressive elastic modulus to rise by around 72%. It is concluded that the printing parameters and process must be tuned very well in fabricating scaffolds with the desired morphology and mechanical property.     

Influence of fused deposition modeling parameters on the mechanical properties of ABS parts

This work aims to determine the influence of fused deposition modeling (FDM) printing parameters on the mechanical properties of parts fabricated on an Ultimaker2 printer with acrylonitrile butadiene styrene (ABS). The effect of several parameters such as interlayer cooling time (ILCT), nozzle diameter, infill density, raster angle and layer thickness on the ultimate tensile strength, yield strength, and elastic modulus of produced parts was evaluated. Two independent studies were conducted: a first study dedicated to the ILCT and a second study where the influence of other parameters was evaluated through a design of experiments (DoE) approach. Both studies were carried out through the execution of standard tensile tests. The statistical analysis of tensile tests results was processed with the ANOVA methodology. The obtained results indicate that a reduced ILCT improves the tensile strength of parts. It is shown that nozzle diameter and infill density are the parameters that most influence the mechanical properties of ABS, with the upper range selected values improving the studied mechanical properties. The raster angle configuration of (?45^o/45^o) benefits UTS and yield strength of ABS samples. Interactions of nozzle diameter on layer thickness were detected. It was observed that smaller layer thickness promotes a higher elastic modulus and UTS; however, for thinner layers (0.06‐0.10 mm), no significant differences were found on strength of samples due to potential high distortion levels.     

Evaluation of 3D Printed Gelatin‐Based Scaffolds with Varying Pore Size for MSC‐Based Adipose Tissue Engineering

Adipose tissue engineering aims to provide solutions to patients who require tissue reconstruction following mastectomies or other soft tissue trauma. Mesenchymal stromal cells (MSCs) robustly differentiate into the adipogenic lineage and are attractive candidates for adipose tissue engineering. This work investigates whether pore size modulates adipogenic differentiation of MSCs toward identifying optimal scaffold pore size and whether pore size modulates spatial infiltration of adipogenically differentiated cells. To assess this, extrusion‐based 3D printing is used to fabricate photo‐crosslinkable gelatin‐based scaffolds with pore sizes in the range of 200–600 µm. The adipogenic differentiation of MSCs seeded onto these scaffolds is evaluated and robust lipid droplet formation is observed across all scaffold groups as early as after day 6 of culture. Expression of adipogenic genes on scaffolds increases significantly over time, compared to TCP controls. Furthermore, it is found that the spatial distribution of cells is dependent on the scaffold pore size, with larger pores leading to a more uniform spatial distribution of adipogenically differentiated cells. Overall, these data provide first insights into the role of scaffold pore size on MSC‐based adipogenic differentiation and contribute toward the rational design of biomaterials for adipose tissue engineering in 3D volumetric spaces.     

Non‐Lithography Hydrodynamic Printing of Micro/Nanostructures on Curved Surfaces

A key issue of micro/nano devices is how to integrate micro/nanostructures with specified chemical components onto various curved surfaces. Hydrodynamic printing of micro/nanostructures on three‐dimensional curved surfaces is achieved with a strategy that combines template‐induced hydrodynamic printing and self‐assembly of nanoparticles (NPs). Non‐lithography flexible wall‐shaped templates are replicated with microscale features by dicing a trench‐shaped silicon wafer. Arising from the capillary pumped function between the template and curved substrates, NPs in the colloidal suspension self‐assemble into close‐packed micro/nanostructures without a gravity effect. Theoretical analysis with the lattice Boltzmann model reveals the fundamental principles of the hydrodynamic assembly process. Spiral linear structures achieved by two kinds of fluorescent NPs show non‐interfering photoluminescence properties, while the waveguide and photoluminescence are confirmed in 3D curved space. The printed multiconstituent micro/nanostructures with single‐NP resolution may serve as a general platform for optoelectronics beyond flat surfaces.     

3D Printing in analytical sample preparation

In the last 5 years, additive manufacturing (three‐dimensional printing) has emerged as a highly valuable technology to advance the field of analytical sample preparation. Three‐dimensional printing enabled the cost‐effective and rapid fabrication of devices for sample preparation, especially in flow‐based mode, opening new possibilities for the development of automated analytical methods. Recent advances involve membrane‐based three‐dimensional printed separation devices fabricated by print‐pause‐print and multi‐material three‐dimensional printing, or improved three‐dimensional printed holders for solid‐phase extraction containing sorbent bead packings, extraction disks, fibers, and magnetic particles. Other recent developments rely on the direct three‐dimensional printing of extraction sorbents, the functionalization of commercial three‐dimensional printable resins, or the coating of three‐dimensional printed devices with functional micro/nanomaterials. In addition, improved devices for liquid–liquid extraction such as extraction chambers, or phase separators are opening new possibilities for analytical method development combined with high‐performance liquid chromatography. The present review outlines the current state‐of‐the‐art of three‐dimensional printing in analytical sample preparation.     

The influence of grafted cellulose nanofibers and postextrusion annealing treatment on selected properties of poly(lactic acid) filaments for 3D printing

l ‐lactide monomers were grafted onto cellulose nanofibers (CNFs) via ring‐opening polymerization, forming poly(lactic acid) grafted cellulose nanofibers (PLA‐g‐CNFs). PLA‐g‐CNFs and pristine PLA were then blended in chloroform and dried to prepare a master batch. PLA‐g‐CNFs/PLA composite filaments targeted for 3D printing were produced by compounding the master batch in PLA matrix and melt extrusion. The as‐extruded composite filaments were subsequently thermal annealed in a conventional oven, and their morphological, thermal, and mechanical properties were evaluated. PLA was successfully grafted on the surface of CNFs as demonstrated by elemental analysis, and the concentration of grafted PLA was estimated to be 33 wt %. The grafted PLA were highly crystallized, contributing to the growth of crystalline regions of PLA matrix. The incorporation of PLA‐g‐CNFs improved storage modulus of the composite filaments in both low temperature glassy state and high temperature rubbery state. Postextrusion annealing treatment led to 28 and 63% increases for tensile modulus and strength of the filaments, respectively. Simulated Young's moduli from the Halpin‐Tsai and Krenchel models were found comparable with the experimental values. The formed composite filaments are suitable for use in 3D printing. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2017 , 55, 847–855