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As the understanding of disease grows, so does the opportunity for personalization of therapies targeted to the needs of the individual. To bring about a step change in the personalization of medical devices it is shown that multi-material inkjet-based 3D printing can meet this demand by combining functional materials, voxelated manufacturing, and algorithmic design. In this paper composite structures designed with both controlled deformation and reduced biofilm formation are manufactured using two formulations that are deposited selectively and separately. The bacterial biofilm coverage of the resulting composites is reduced by up to 75% compared to commonly used silicone rubbers, without the need for incorporating bioactives. Meanwhile, the composites can be tuned to meet user defined mechanical performance with ±10% deviation. Device manufacture is coupled to finite element modelling and a genetic algorithm that takes the user-specified mechanical deformation and computes the distribution of materials needed to meet this under given load constraints through a generative design process. Manufactured products are assessed against the mechanical and bacterial cell-instructive specifications and illustrate how multifunctional personalization can be achieved using generative design driven multi-material inkjet based 3D printing.

Three-dimensional lattices have applications across a range of fields including structural lightweighting, impact absorption and biomedicine. In this work, lattices based on triply periodic minimal surfaces were produced by polymer additive manufacturing and examined with a combination of experimental and computational methods. This investigation elucidates their deformation mechanisms and provides numerical parameters crucial in establishing relationships between their geometries and mechanical performance. Three types of lattice were examined, with one, known as the primitive lattice, being found to have a relative elastic modulus over twice as large as those of the other two. The deformation process of the primitive lattice was also considerably different from those of the other two, exhibiting strut stretching and buckling, while the gyroid and diamond lattices deformed in a bending dominated manner. Finite element predictions of the stress distributions in the lattices under compressive loading agreed with experimental observations. These results can be used to create better informed lattice designs for a range of mechanical and biomedical applications.

A new type of photocrosslinkable polycaprolactone (PCL)-based ink that is suitable for three-dimensional (3D) inkjet printing has been developed. Photocrosslinkable PCL dimethylacrylate was synthesized and mixed with poly(ethylene glycol) diacrylate to prepare an ink with a suitable viscosity for inkjet printing. The ink performance under different printing environments, initiator concentrations, and postprocess was studied. This showed that a nitrogen atmosphere during printing was beneficial for curing and material property optimization, as well as improving the quality of structures produced. A simple structure, building in the z-direction, demonstrated the potential for thismaterial for the production of 3D printed objects. Cells’ testwas carried out to investigate the biocompatibility of the developed ink.

Additive manufacturing (AM) technology is capable of building up component geometry in a layer-by-layer process, entirely without tools, molds, or dies. One advantage of the approach is that it is capable of efficiently creating complex product geometry. Using experimental data collected during the manufacture of a titanium test part on a variant of AM technology, electron beam melting (EBM), this research studies the effect of a variation in product shape complexity on process energy consumption. This is done by applying a computationally quantifiable convexity-based characteristic associated with shape complexity to the test part and correlating this quantity with per-layer process energy consumption on the EBM system. Only a weak correlation is found between the complexity metric and energy consumption (ρ = .35), suggesting that process energy consumption is indeed not driven by shape complexity. This result is discussed in the context of the energy consumption of computer-controlled machining technology, which forms an important substitute to EBM. This article further discusses the impact of available additional shape complexity at the manufacturing process level on the incentives toward minimization of energy inputs, additional benefits arising later within the product’s life cycle, and its implications for value creation possibilities.