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In this work, a 3D printed biocompatible micro-optofluidic (MoF) device for two-phase flow monitoring is presented. Both an air–water bi-phase flow and a two-phase mixture composed of micrometric cells suspended on a liquid solution were successfully controlled and monitored through its use. To manufacture the MoF device, a highly innovative microprecision 3D printing technique was used named Projection Microstereolithography (P μ SL) in combination with the use of a novel 3D printable photocurable resin suitable for biological and biomedical applications. The concentration monitoring of biological fluids relies on the absorption phenomenon. More precisely, the nature of the transmission of the light strictly depends on the cell concentration: the higher the cell concentration, the lower the optical acquired signal. To achieve this, the microfluidic T-junction device was designed with two micrometric slots for the optical fibers' insertion, needed to acquire the light signal. In fact, both the micro-optical and the microfluidic components were integrated within the developed device. To assess the suitability of the selected biocompatible transparent resin for optical detection relying on the selected working principle (absorption phenomenon), a comparison between a two-phase flow process detected inside a previously fully characterized micro-optofluidic device made of a nonbiocompatible high-performance resin (HTL resin) and the same made of the biocompatible one (BIO resin) was carried out. In this way, it was possible to highlight the main differences between the two different resin grades, which were further justified with proper chemical analysis of the used resins and their hydrophilic/hydrophobic nature via static water contact angle measurements. A wide experimental campaign was performed for the biocompatible device manufactured through the P μ SL technique in different operative conditions, i.e., different concentrations of eukaryotic yeast cells of Saccharomyces cerevisiae (with a diameter of 5 μ m) suspended on a PBS (phosphate-buffered saline) solution. The performed analyses revealed that the selected photocurable transparent biocompatible resin for the manufactured device can be used for cell concentration monitoring by using ad hoc 3D printed micro-optofluidic devices. In fact, by means of an optical detection system and using the optimized operating conditions, i.e., the optimal values of the flow rate F R = 0.1 mL/min and laser input power P ∈ { 1 , 3 } mW, we were able to discriminate between biological fluids with different concentrations of suspended cells with a robust working ability R 2 = 0.9874 and R a d j 2 = 0.9811 . [ABSTRACT FROM AUTHOR]

In this work, a quadratic polynomial regression model was developed to aid practitioners in the determination of the refractive index value of transparent 3D printable photocurable resins usable for micro-optofluidic applications. The model was experimentally determined by correlating empirical optical transmission measurements (the dependent variable) to known refractive index values (the independent variable) of photocurable materials used in optics, thus obtaining a related regression equation. In detail, a novel, simple, and cost-effective experimental setup is proposed in this study for the first time for collecting the transmission measurements of smooth 3D printed samples (roughness ranging between 0.04 and 2 μm). The model was further used to determine the unknown refractive index value of novel photocurable resins applicable in vat photopolymerization (VP) 3D printing techniques for manufacturing micro-optofluidic (MoF) devices. In the end, this study proved how knowledge of this parameter allowed us to compare and interpret collected empirical optical data from microfluidic devices made of more traditional materials, i.e., Poly(dimethylsiloxane) (PDMS), up to novel 3D printable photocurable resins suitable for biological and biomedical applications. Thus, the developed model also provides a quick method to evaluate the suitability of novel 3D printable resins for MoF device fabrication within a well-defined range of refractive index values (1.56; 1.70). [ABSTRACT FROM AUTHOR]

In microfluidics, it is important to confine and transport light as close as possible to the sample by guiding it into a small volume of the microfluidic channel, acquiring the emitted/transmitted radiation. A challenge in this context is the miniaturization of the optical components and their integration into the microfluidic device. Among all of the optical components, a particular role is played by the beam splitter, an important optical device capable of splitting light into several paths. In this paper, a micro-splitter is designed and realized by exploiting low-cost technologies. The micro-splitter consists of a micro-mirror in-between two micro-waveguides. This component was fabricated in different materials: poly-dimethyl-siloxane (PDMS), poly(methyl methacrylate) (PMMA), and VeroClear RGD810. A 3D printing master–slave fabrication protocol was used with PDMS, a direct 3D printing approach with VeroClear, and a laser cutting procedure with PMMA. The experimental results obtained show the high potential of the proposed fabrication protocols, based on low-cost technologies, for the realization of micro-optical components, which could also be easily integrated with microfluidics systems. [ABSTRACT FROM AUTHOR]

In this work, the authors aimed to identify a potential correlation between the printability and crucial rheological characteristics of materials involved in fused deposition modeling (FDM) technology. In this regard, three different poly(lactide) acid (PLA)-based filaments (two commercially available (here called V-PLA and R-PLA) and one processed in a lab-scale extruder (here called L-PLA)) have been considered. Dynamic rheological testing, in terms of frequency sweep at five different temperatures (130, 150, 170, 190, and 210 °C), was performed. Rheological properties expressed in terms of viscoelastic moduli and complex viscosity curves vs. frequency, characteristic relaxation times, activation energy (Ea), zero shear viscosity ( η 0 ) and shear thinning index (n) were derived for each material. A characteristic relaxation time of around 0.243 s was found for V-PLA, a similar value (0.295 s) was calculated for R-PLA filaments, and a lower value of about an order of magnitude was calculated for L-PLA filament (~0.0303 s). The activation energy and shear thinning index resulted to be very comparable for all the filaments. On the contrary, V-PLA and R-PLA possessed a zero-shear viscosity (~104 Pa*s at 170 °C) much higher than L-PLA (~103 Pa*s). All the filaments were processed in a 3D printer, by attesting the effect of nozzle temperature (180, 190, and 210 °C, respectively) on printing process, and macroscopic shaping defects in printed objects. Final considerations allowed us to conclude that polymer relaxation time, zero-shear viscosity, and melt viscosity (affected by printing temperature) were critical parameters affecting the printing quality. [ABSTRACT FROM AUTHOR]

In this paper, a hybrid commercially available alumina/polymer filament was 3D printed and thermally treated (debinding and sintering) to obtain ceramic parts. Microscopic and spectroscopic analysis was used to thoroughly characterize the green and sintered parts in terms of their mesostructured, as well as their flexural properties. The sintered samples show an α alumina crystalline phase with a mean density of 3.80 g/cm3, a tensile strength of 232.6 ± 12.3 MPa, and a Vickers hardness of 21 ± 0.7 GPa. The mean thermal conductivity value at room temperature was equal to 21.52 ± 0.02 W/(mK). The values obtained through FFF production are lower than those obtained by conventional processes as the 3D-printed samples exhibited imperfect interlayer bonding and voids similar to those found in the structures of polymeric FFFs. Nonetheless, the highly filled ceramic filament is suitable for use in affordable and easy-to-operate FFF machines, as shown by the cost analysis of a real printed and sintered FFF part. [ABSTRACT FROM AUTHOR]

Commercial available filaments made from poly(lactic) acid (PLA) are selected for potential use in 3D printed parts by fused deposition modeling. Virgin materials (PLA Eum, Z‐PLA Pro), but also recycled matrices (PLA 2Life, PLA Eubio), and one filled with wood fibers (PLA Woodfir) have been considered. Then, a lab‐made filament (PLA Nature) is realized by extruding PLA pellets. Thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and rheological measurements are used to determine initial degradation temperature, glass transition, melting temperature, and complex viscosity as a function of time and material pre‐drying. A preliminary investigation of thermal properties enables the materials' processing window to be validated in order to prevent the deterioration during the process. PLA Nature and PLA Woodfir melt around 170°C, whereas all of the other biopolymers show a lower melting point (around 150°C). The temperature at which thermal degradation began is always greater than 260°C. However, good stability of rheological parameters over time at 210°C is not confirmed for all bio‐filaments. In particular, for Z‐PLA Pro and PLA Eubio, a significant reduction of complex viscosity is verified after a few seconds of testing. Drying samples have been shown to improve the long‐term stability of complex viscosity. [ABSTRACT FROM AUTHOR]

Metal 3D-printed parts are critical in industries such as biomedical, surgery, and prosthetics to create tailored components for patients, but the costs associated with traditional metal additive manufacturing (AM) techniques are typically prohibitive. To overcome this disadvantage, more cost-effective manufacturing processes are needed, and a good approach is to combine fused deposition modeling (FDM) with debinding-sintering processes. Furthermore, optimizing the printing parameters is required to improve material density and mechanical performance. The design of experiment (DoE) technique was used to evaluate the impact of three printing factors, namely nozzle temperature, layer thickness, and flow rate, on the tensile and bending properties of sintered 316L stainless steel in this study. Green and sintered samples were morphologically and physically characterized after printing, and the optimal printing settings were determined by statistical analysis, which included the surface response technique. The mechanical properties of the specimens increased as the flow rate and layer thickness increased and the nozzle temperature decreased. The optimized printing parameters for the ranges used in this study include 110% flow rate, 140 μm layer thickness, and 240 °C nozzle temperature, which resulted in sintered parts with a tensile strength of 513 MPa and an elongation at break of about 60%. [ABSTRACT FROM AUTHOR]

Tailored ZnO surface functionalization was performed inside a polydimethyl-siloxane (PDMS) microchannel of a micro-optofluidic device (mofd) to modulate its surface hydrophobicity to develop a method for fine tuning the fluid dynamics inside a microchannel. The wetting behavior of the surface is of particular importance if two different phases are used for system operations. Therefore, the fluid dynamic behavior of two immiscible fluids, (i) air–water and (ii) air–glycerol/water in PDMS mofds and ZnO-PDMS mofds was investigated by using different experimental conditions. The results showed that air–glycerol/water fluid was always faster than air–water flow, despite the microchannel treatment: however, in the presence of ZnO microstructures, the velocity of the air–glycerol/water fluid decreased compared with that observed for the air–water fluid. This behavior was associated with the strong ability of glycerol to create an H-bond network with the exposed surface of the zinc oxide microparticles. The results presented in this paper allow an understanding of the role of ZnO functionalization, which allows control of the microfluidic two-phase flow using different liquids that undergo different chemical interactions with the surface chemical terminations of the microchannel. This chemical approach is proposed as a control strategy that is easily adaptable for any embedded micro-device. [ABSTRACT FROM AUTHOR]

This research focuses on the thermal characterization of 3D-printed parts obtained via fused filament fabrication (FFF) technology, which uses a poly(lactic acid) (PLA)-based filament filled with milled carbon fibers (MCF) from pyrolysis at different percentages by weight (10, 20, 30 wt%). Differential scanning calorimetry (DSC) and thermal conductivity measurements were used to evaluate the thermal characteristics, morphological features, and heat transport behavior of the printed specimens. The experimental results showed that the addition of MCF to the PLA matrix improved the conductive properties. Scanning electron microscopy (SEM) micrographs were used to obtain further information about the porosity of the systems. [ABSTRACT FROM AUTHOR]

Featured Application: The development of hybrid metal/polymer filaments opens the possibility to expand metal 3D printing with investment costs accessible to small and medium enterprises. This will allow 3D printing of metal parts with the same approach used for desktop 3D printing, thus further democratizing the use of additive manufacturing in applications that cannot be fulfilled by polymeric 3D printing. The exploitation of mechanical properties and customization possibilities of 3D printed metal parts usually come at the cost of complex and expensive equipment. To address this issue, hybrid metal/polymer composite filaments have been studied allowing the printing of metal parts by using the standard Fused Filament Fabrication (FFF) approach. The resulting hybrid metal/polymer part, the so called "green", can then be transformed into a dense metal part using debinding and sintering cycles. In this work, we investigated the manufacturing and characterization of green and sintered parts obtained by FFF of two commercial hybrid metal/polymer filaments, i.e., the Ultrafuse 316L by BASF and the 17-4 PH by Markforged. The Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectrometry (EDS) analyses of the mesostructure highlighted incomplete raster bonding and voids like those observed in conventional FFF-printed polymeric structures despite the sintering cycle. A significant role in the tensile properties was played by the building orientation, with samples printed flatwise featuring the highest mechanical properties, though lower than those achievable with standard metal additive manufacturing techniques. [ABSTRACT FROM AUTHOR]

In this work, a novel approach to realize a plasmonic sensor is presented. The proposed optical sensor device is designed, manufactured, and experimentally tested. Two photo-curable resins are used to 3D print a surface plasmon resonance (SPR) sensor. Both numerical and experimental analyses are presented in the paper. The numerical and experimental results confirm that the 3D printed SPR sensor presents performances, in term of figure of merit (FOM), very similar to other SPR sensors made using plastic optical fibers (POFs). For the 3D printed sensor, the measured FOM is 13.6 versus 13.4 for the SPR-POF configuration. The cost analysis shows that the 3D printed SPR sensor can be manufactured at low cost (∼15 €) that is competitive with traditional sensors. The approach presented here allows to realize an innovative SPR sensor showing low-cost, 3D-printing manufacturing free design and the feasibility to be integrated with other optical devices on the same plastic planar support, thus opening undisclosed future for the optical sensor systems. [ABSTRACT FROM AUTHOR]

Fused deposition modeling (FDM) is currently the most popular 3D printing method, where thermoplastic polymers are predominantly used. Among them, the biobased poly(lactic acid) (PLA) governs the FDM filament market, with demand higher than supply, since not all grades of PLA are suitable for FDM filament production. In this work, the effect of a food grade chain extender (Joncryl ADR® 4400) on the physicochemical properties and printability of PLA marketed for injection molding was examined. All samples were characterized in terms of their mechanical and thermal properties. The microstructure of the filaments and 3D-printed fractured surfaces following tensile testing were examined with optical and scanning electron microscopy, respectively. Molecular weight and complex viscosity increased, while the melt flow index decreased after the incorporation of Joncryl, which resulted in filaments of improved quality and 3D-printed constructs with enhanced mechanical properties. Dielectric spectroscopy revealed that the bulk properties of PLA with respect to molecular mobility, both local and segmental, were, interestingly, not affected by the modifier. Indirectly, this may suggest that the major effects of the extender are on chain length, without inducing chain branching, at least not to a significant extent. [ABSTRACT FROM AUTHOR]

Three commercial filaments for Fused Deposition Modeling (FDM) were selected to study the influence of polymer formulation on the printing quality and mechanical properties of FDM specimens. The three filaments were all based on polylactic acid (PLA) as the matrix, and they are sold as PLA filaments. The printing quality was tested by printing one complex shape with overhang features. The marked shear thinning behavior for two filaments was observed by rheology. The filaments were also studied by scanning electron microscopy and thermogravimetric analysis (TGA) to unveil their composition. The filaments with the best printing quality showed the presence of mineral fillers, which explained the melt behavior observed by rheology. The tensile testing confirmed that the filled PLA was the best-performing filament both in terms of printing quality and thermomechanical performance, with a p-value = 0.106 for the tensile modulus, and a p-value = 0.615 for the ultimate tensile strength. [ABSTRACT FROM AUTHOR]