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Additive manufacturing (AM) has created a new era of digital manufacturing, where engineering practices, computer-aided design platforms, and part sourcing pipelines are dramatically changing. AM techniques are capable of producing plastic, metal, and ceramic components for both prototyping and end-use purposes. In this review, the fabrication of dense, structural advanced ceramic components using the seven families of additive manufacturing is discussed through a historical perspective. Initial studies on additive manufacturing of ceramic materials were reported just a few years after those of metal and plastic materials. However, industrial application of ceramic additive manufacturing is more than a decade behind metallic and plastic materials. Many of the challenges of ceramic AM can be traced back to the intrinsic difficulties of processing structural ceramic materials, including high processing temperatures, defect-sensitive mechanical properties, and poor machining characteristics. To mature the field of ceramic AM, future research and development should focus on expanding material selection, improving printing and post-processing control, realizing single-step processing, and unique capabilities such as multi-material and hybrid processing.

Purpose There are over 40 million amputees globally with more than 185,000 Americans losing their limbs every year. For most of the world, prosthetic devices remain too expensive and uncomfortable. This paper aims to outline advancements made by a multidisciplinary research group, interested in advancing the restoration of human motion through accessible lower limb prostheses. Design/methodology/approach Customization, comfort and functionality are the most important metrics reported by prosthetists and patients. The work of this paper presents the design and manufacturing of a custom made, cost-effective and functional three-dimensional (3D) printed transtibial prosthesis monocoque design. The design of the prosthesis integrates 3D imaging, modelling and optimization techniques coupled with additive manufacturing. Findings The successful fabrication of a functional monocoque prosthesis through 3D printing indicates the workflow may be a solution to the worldwide accessibility crisis. The digital workflow developed in this work offers great potential for providing prosthetic devices to rural communities, which lack access to skilled prosthetic physicians. The authors found that using the workflow together with 3D printing, this study can create custom monocoque prostheses (Figure 16). These prostheses are comfortable, functional and properly aligned. In comparison with traditional prosthetic devices, the authors slowered the average cost, weight and time of production by 95%, 55% and 95%, respectively. Social implications This novel digital design and manufacturing workflow has the potential to democratize and globally proliferate access to prosthetic devices, which restore the patient’s mobility, quality of life and health. LIMBER’s toolbox can reach places where proper prosthetic and orthotic care is not available. The digital workflow reduces the cost of making custom devices by an order of magnitude, enabling broader reach, faster access and improved comfort. This is particularly important for children who grow quickly and need new devices every few months or years, timely access is both physically and psychologically important. Originality/value In this manuscript, the authors show the application of digital design techniques for fabricating prosthetic devices. The proposed workflow implements several advantageous changes and, most importantly, digitally blends the three components of a transtibial prosthesis into a single, 3D printable monocoque device. The development of a novel unibody transtibial device that is properly aligned and adjusted digitally, greatly reduces the number of visits an amputee must make to a clinic to have a certified prosthetist adjust and modify their prosthesis. The authors believe this novel workflow has the potential to ease the worldwide accessibility crisis for prostheses.

Advanced ceramics are required in many applications including armor, engine components, and wear parts for abrasive, corrosive, and high temperature environments. Heterogeneous structuring in these materials has the potential to unlock extrinsic mechanisms that improve damage tolerance, of vital importance for structural functionality. However, traditional ceramic powder processing and forming techniques limit the design space to simple geometries with chemically homogenous microstructures. Thus, additive manufacturing by direct ink writing (DIW) was applied to fabricate multi-phase carbide specimens with tailored composition and mesostructure. A custom DIW system was developed to allow simultaneous extrusion and mixing of multiple inks, comprised of ceramic particulate suspensions, through a single nozzle. Boron carbide (B4C) and silicon carbide (SiC) were chosen for this study due to their excellent mechanical properties. Aqueous B4C and SiC inks were loaded to 47.5 vol% ceramic content and showed yield-pseudoplastic behavior. The carbide inks were characterized and modified to exhibit similar rheological behavior (yield stress and viscosity), and were used to produce B4C–SiC parts with either discrete or continuous composition variation. Specimens were hot pressed at 35 MPa and 1950 °C, yielding near full density with hardness (Knoop) values of 20–23 GPa. Tailored heterogeneity, achieved via active in-line mixing, is revealed through microstructural characterization. Cracking observed in the specimen with discretely varied composition is the result of thermally-induced residual stress, and is elucidated through analytical calculations.

Sample preparation is critical to biological electron microscopy (EM), and there have been continuous efforts on optimizing the procedures to best preserve structures of interest in the sample. However, a quantitative characterization of the morphological changes associated with each step in EM sample preparation is currently lacking. Using correlative EM and superresolution microscopy (SRM), we have examined the effects of different drying methods as well as osmium tetroxide (OsO4) post-fixation on cell morphology during scanning electron microscopy (SEM) sample preparation. Here, SRM images of the sample acquired under hydrated conditions were used as a baseline for evaluating morphological changes as the sample went through SEM sample processing. We found that both chemical drying and critical point drying lead to a mild cellular boundary retraction of ~60 nm. Post-fixation by OsO4 causes at least 40 nm additional boundary retraction. We also found that coating coverslips with adhesion molecules such as fibronectin prior to cell plating helps reduce cell distortion from OsO4 post-fixation. These quantitative measurements offer useful information for identifying causes of cell distortions in SEM sample preparation and improving current procedures.