Freedom of design, mass customisation, waste minimisation and the ability to manufacture complex structures, as well as fast prototyping, are the main benefits of additive manufacturing (AM) or 3D printing. A comprehensive review of the main 3D printing methods, materials and their development in trending applications was carried out. In particular, the revolutionary applications of AM in biomedical, aerospace, buildings and protective structures were discussed. The current state of materials development, including metal alloys, polymer composites, ceramics and concrete, was presented. In addition, this paper discussed the main processing challenges with void formation, anisotropic behaviour, the limitation of computer design and layer-by-layer appearance. Overall, this paper gives an overview of 3D printing, including a survey on its benefits and drawbacks as a benchmark for future research and development.

Additive manufacturing (3D printing): A review of materials, methods, applications and challenges

Additive manufacturing (AM) alias 3D printing translates computer-aided design (CAD) virtual 3D models into physical objects. By digital slicing of CAD, 3D scan, or tomography data, AM builds objects layer by layer without the need for molds or machining. AM enables decentralized fabrication of customized objects on demand by exploiting digital information storage and retrieval via the Internet. The ongoing transition from rapid prototyping to rapid manufacturing prompts new challenges for mechanical engineers and materials scientists alike. Because polymers are by far the most utilized class of materials for AM, this Review focuses on polymer processing and the development of polymers and advanced polymer systems specifically for AM. AM techniques covered include vat photopolymerization (stereolithography), powder bed fusion (SLS), material and binder jetting (inkjet and aerosol 3D printing), sheet lamination (LOM), extrusion (FDM, 3D dispensing, 3D fiber deposition, and 3D plotting), and 3D bioprinting....

Polymers for 3D Printing and Customized Additive Manufacturing

Organ printing can be defined as layer-by-layer additive robotic biofabrication of three-dimensional functional living macrotissues and organ constructs using tissue spheroids as building blocks. The microtissues and tissue spheroids are living materials with certain measurable, evolving and potentially controllable composition, material and biological properties. Closely placed tissue spheroids undergo tissue fusion - a process that represents a fundamental biological and biophysical principle of developmental biology-inspired directed tissue self-assembly. It is possible to engineer small segments of an intraorgan branched vascular tree by using solid and lumenized vascular tissue spheroids. Organ printing could dramatically enhance and transform the field of tissue engineering by enabling large-scale industrial robotic biofabrication of living human organ constructs with "built-in" perfusable intraorgan branched vascular tree. Thus, organ printing is a new emerging enabling technology paradigm which represents a developmental biology-inspired alternative to classic biodegradable solid scaffold-based approaches in tissue engineering.

Organ Printing: Tissue Spheroids as Building Blocks

The field of 3D printing is continuing its rapid development in both academic and industrial research environments. The development of 3D printing technologies has opened new implementations in rapid prototyping, tooling, dentistry, microfluidics, biomedical devices, tissue engineering, drug delivery, etc. Among different 3D printing techniques, photopolymerization-based process (such as stereolithography and digital light processing) offers flexibility over the final properties of the 3D printed materials (such as optical, chemical, and mechanical properties) using versatile polymer chemistry. The strategy behind the 3D photopolymerization is based on using monomers/oligomers in liquid state (in the presence of photoinitiators) that can be photopolymerized (via radical or cationic mechanism) upon exposure to light source of different wavelengths (depending on the photoinitiator system). An overview of recent evolutions in the field of photopolymerization-based 3D printing and highlights of novel 3D print...

Photopolymerization in 3D Printing

Organs are complex systems composed of different cells, proteins and signalling molecules that are arranged in a highly ordered structure to orchestrate a myriad of functions in our body. Biofabrication strategies can be applied to engineer 3D tissue models in vitro by mimicking the structure and function of native tissue through the precise deposition and assembly of materials and cells. This approach allows the spatiotemporal control over cell–cell and cell–extracellular matrix communication and thus the recreation of tissue-like structures. In this Review, we examine biofabrication strategies for the construction of functional tissue replacements and organ models, focusing on the development of biomaterials, such as supramolecular and photosensitive materials, that can be processed using biofabrication techniques. We highlight bioprinted and bioassembled tissue models and survey biofabrication techniques for their potential to recreate complex tissue properties, such as shape, vasculature and specific functionalities. Finally, we discuss challenges, such as scalability and the foreign body response, and opportunities in the field and provide an outlook to the future of biofabrication in regenerative medicine. Biofabrication can be applied to replicate tissues and organs for regenerative medicine and for the creation of 3D in vitro tissue models. In this Review, the recent advances in biomaterials and biofabrication technologies are discussed, and challenges and opportunities are highlighted.

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Biofabrication strategies for 3D in vitro models and regenerative medicine

A novel family of optically transparent acrylic nanocomposites containing up to 30 wt % silica nanoparticles with an average diameter of 20 nm was developed for application in structural light modulation (SLM) and stereolithography (SL) technologies. The uniform dispersion of nanoparticles affords a significantly improved toughness/stiffness-balance of the photopolymerized and postcured nanocomposites. It is possible to increase stiffness, as expressed by Young's modulus, from 1290 to 1700 MPa without encountering the embrittlement typical for many other conventional filled polymers. Fracture behaviour is examined by means of fracture mechanics investigation and SEM analyses of fracture surfaces. According to TEM analyses and measurement of optical transmittance remarkable uniform dispersion of silica nanoparticles was achieved. The silica nanoparticle concentrations up to 17 wt % give only marginally higher viscosities and do not affect transmittance, while slightly increasing the exposure times needed in photopolymerization. Moreover, the silica nanoparticles afford materials with reduced shrinkage and improved properties. The green effective ankle splay out (EASO) measured on H-shaped diagnostic specimens, is significantly reduced for the nanocomposite materials from 1.38 mm for the unfilled material to 0.82 mm for nanocomposites containing 30 wt % nanosilica. The building accuracy is increased significantly with increasing content of silica nanofillers.

Acrylic Nanocomposite Resins for Use in Stereolithography and Structural Light Modulation Based Rapid Prototyping and Rapid Manufacturing Technologies

Novel acrylic nanocomposites containing in-situ formed calcium phosphate/layered silicate hybrid nanoparticles for photochemical rapid prototyping, rapid tooling and rapid manufacturing processes

Poly(methyl methacrylate) (PMMA), polystyrene (PS), and polyurethane (PU) nanocomposites containing well-dispersed calcium phosphate/layered silicate hybrid nanoparticles were prepared in a versatile solvent-free “one-pot” process without requiring separate steps, such as organophilic modification, purification, drying, dispersing, and compounding, typical for many conventional organoclay nanocomposites. In this “one-pot” process, alkyl ammonium phosphates were added as swelling agents to a suspension of calcium/layered silicate in styrene, methyl methacrylate, or polyols prior to polymerization. Alkyl ammonium phosphates were prepared in situ by reacting phosphoric acid with an equivalent amount of alkyl amines such as stearyl amine (SA) or the corresponding ester- and methacrylate-functionalized tertiary alkyl amines, obtained via Michael Addition of SA with methyl acrylate or ethylene 2-methacryloxyethyl acrylate. Upon contact with the calcium bentonite suspension, the cation exchange of Ca2+ in the silicate interlayers for alkyl ammonium cations rendered the bentonite organophilic and enabled effective swelling in the monomer accompanied by intercalation and in situ precipitation of calcium phosphates. According to energy dispersive X-ray analysis, the calcium phosphate precipitated exclusively onto the surfaces of the bentonite nanoplatelets, thus forming easy-to-disperse calcium phosphate/layered silicate hybrid nanoparticles. Incorporation of 5–15 wt% of such hybrid nanoparticles into PMMA, PS, and PU afforded improved stiffness/toughness balances of the polymer nanocomposites. Functionalized alkyl ammonium phosphate addition enabled polymer attachment to the nanoparticle surfaces. Transmission electron microscopy (TEM) analyses of PU and PU-foam nanocomposites, prepared by dispersing hybrid nanoparticles in the polyols prior to isocyanate cure, revealed the formation of fully exfoliated hybrid nanoparticles.

A Versatile Solvent‐Free “One‐Pot” Route to Polymer Nanocomposites and the in situ Formation of Calcium Phosphate/Layered Silicate Hybrid Nanoparticles

Matthias Gurr

Papers

Polymers for 3D Printing and Customized Additive Manufacturing

Acrylic Nanocomposite Resins for Use in Stereolithography and Structural Light Modulation Based Rapid Prototyping and Rapid Manufacturing Technologies

Novel acrylic nanocomposites containing in-situ formed calcium phosphate/layered silicate hybrid nanoparticles for photochemical rapid prototyping, rapid tooling and rapid manufacturing processes

A Versatile Solvent‐Free “One‐Pot” Route to Polymer Nanocomposites and the in situ Formation of Calcium Phosphate/Layered Silicate Hybrid Nanoparticles