Additive manufacturing (AM) of polymer composites with continuous fibers could play a major role in the future of aerospace and beyond but will require printed materials to achieve new levels of reliability. This study characterized the strength distribution of selected thermoplastic matrix composites as a func- tion of printing via fused filament fabrication (FFF). Experimental and commercial composite filaments of continuous carbon or Kevlar fibers were printed with volume fraction (Vf) ranging from approximately 28 to 56 %. The strength was evaluated under uniaxial tension after specific stages of printing and Weibull statistics were applied to characterize the strength distribution. There was a significant reduction in strength of the printed material with respect to the unprinted condition, regardless of reinforcement type, fiber volume fraction or printer used. Damage introduced by feed extrusion of the filament, and fiber failures induced at material deposition were most detrimental. For carbon fiber filaments, the reduc- tion ranged from approximately 10 % for an experimental material to over 60 % for a commercial filament. There was no correlation in the strength degradation or variability with Vf. The prevention of process-related fiber damage is key to advancing AM for continuous fiber composite and application to designs intended for stress-critical applications.
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Additive Manufacturing of Biomechanically Tailored Meshes for Compliant Wearable and Implantable Devices
Additive manufacturing (AM) of medical devices such as orthopedic implants and hearing aids is highly attractive because of the potential of AM to match the complex form and mechanics of individual human bodies. Externally worn and implantable tissue‐support devices, such as ankle or knee braces, and hernia repair mesh, offer a new opportunity for AM to mimic tissue‐like mechanics and improve both patient outcomes and comfort. Here, it is demonstrated how explicit programming of the toolpath in an extrusion AM process can enable new, flexible mesh materials having digitally tailored mechanical properties and geometry. Meshes are fabricated by extrusion of thermoplastics, optionally with continuous fiber reinforcement, using a continuous toolpath that tailors the elasticity of unit cells of the mesh via incorporation of slack and modulation of filament–filament bonding. It is shown how the tensile mesh mechanics can be engineered to match the nonlinear response of muscle. An ankle brace with directionally specific inversion stiffness arising from embedded mesh is validated, and further concepts for 3D mesh devices are prototyped.
more » « less- Award ID(s):
- 1724135
- NSF-PAR ID:
- 10460206
- Publisher / Repository:
- Wiley Blackwell (John Wiley & Sons)
- Date Published:
- Journal Name:
- Advanced Functional Materials
- Volume:
- 29
- Issue:
- 32
- ISSN:
- 1616-301X
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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Background: Quadriceps weakness is common after anterior cruciate ligament (ACL) reconstruction and can alter gait mechanics. Functional resistance training (FRT) is a novel approach to retraining strength after injury, but it is unclear how it alters gait mechanics. Therefore, we tested how 3 different types of FRT devices: a knee brace resisting extension (unidirectional brace), a knee brace resisting extension and flexion (bidirectional brace), and an elastic band pulling backwards on the ankle (elastic band)–acutely alter gait kinetics in this population.
Hypothesis: The type of FRT device will affect ground-reaction forces (GRFs) during and after the training. Specifically, the uni- and bidirectional braces will increase GRFs when compared with the elastic band.
Study Design: Crossover study.
Level of Evidence: Level 2.
Methods: A total of 15 individuals with ACL reconstruction received FRT with each device over 3 separate randomized sessions. During training, participants walked on a treadmill while performing a tracking task with visual feedback. Sessions contained 5 training trials (180 seconds each) with rest between. Vertical and anterior-posterior GRFs were assessed on the ACL-reconstructed leg before, during, and after training. Changes in GRFs were compared across devices using 1-dimensional statistical parametric mapping.
Results: Resistance applied via bidirectional brace acutely increased gait kinetics during terminal stance/pre-swing (ie, push-off), while resistance applied via elastic band acutely increased gait kinetics during initial contact/loading (ie, braking). Both braces behaved similarly, but the unidirectional brace was less effective for increasing push-off GRFs.
Conclusion: FRT after ACL reconstruction can acutely alter gait kinetics during training. Devices can be applied to selectively alter gait kinetics. However, the long-term effects of FRT after ACL reconstruction with these devices are still unknown.
Clinical Relevance: FRT may be applied to alter gait kinetics of the involved limb after ACL reconstruction, depending on the device used.
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Abstract The ability of living species to transition between rigid and flexible shapes represents one of their survival mechanisms, which has been adopted by various human technologies. Such transition is especially desired in medical devices as rigidity facilitates the implantation process, while flexibility and softness favor biocompatibility with surrounding tissue. Traditional thermoplastics cannot match soft tissue mechanics, while gels leach into the body and alter their properties over time. Here, a single‐component system with an unprecedented drop of Young's modulus by up to six orders of magnitude from the GPa to kPa level at a controlled temperature within 28–43
° C is demonstrated. This approach is based on brush‐like polymer networks with crystallizable side chains, e.g., poly(valerolactone), affording independent control of melting temperature and Young's modulus by concurrently altering side chain length and crosslink density. Softening down to the tissue level at the physiological temperature allows the design of tissue‐adaptive implants that can be inserted as rigid devices followed by matching the surrounding tissue mechanics at body temperature. This transition also enables thermally triggered release of embedded drugs for anti‐inflammatory treatment. -
In this research, we propose a Multi-Filament Fused Deposit Modelling (MFFMD) printer and a respective generator that can be used to produce structural parts with locally tailored functional properties. 3D-printed structural components can highly benefit from multi-material printing with tuneable functional properties. Currently, multi-material printing is mainly achieved using multiple separate nozzles, leading to discontinuous flow in switching materials. This limitation results in material interface delamination, minimal control in the continuous transition of material properties, and longer production time.To address this, we first design and build an MFFMD printer with a single customized nozzle allowing seamless switching between multiple filaments. We then develop a method that generates a continuous toolpath of a given geometry and differentiates materials based on various stress conditions at particular regions. To illustrate, we fabricate a Pratt truss as an example of a tension-compression structure as a case study. In one go, the MFFMD printer deposits resistant filament, respectively, at tension- or compression-concentrated regions based on local stress conditions. Comparative load tests are conducted to validate the performance enhancement of multi-filament prints against single-filament prints. Our proposed method is a prototypical study conducted on a small scale. While it mainly uses thermal plastic filaments, it can be expanded to other construction materials and scales in the future.more » « less
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Abstract Ankle exoskeletons alter whole-body walking mechanics, energetics, and stability by altering center-of-mass (CoM) motion. Controlling the dynamics governing CoM motion is, therefore, critical for maintaining efficient and stable gait. However, how CoM dynamics change with ankle exoskeletons is unknown, and how to optimally model individual-specific CoM dynamics, especially in individuals with neurological injuries, remains a challenge. Here, we evaluated individual-specific changes in CoM dynamics in unimpaired adults and one individual with post-stroke hemiparesis while walking in shoes-only and with zero-stiffness and high-stiffness passive ankle exoskeletons. To identify optimal sets of physically interpretable mechanisms describing CoM dynamics, termed
template signatures , we leveraged hybrid sparse identification of nonlinear dynamics (Hybrid-SINDy), an equation-free data-driven method for inferring sparse hybrid dynamics from a library of candidate functional forms. In unimpaired adults, Hybrid-SINDy automatically identified spring-loaded inverted pendulum-like template signatures, which did not change with exoskeletons (p > 0.16), except for small changes in leg resting length (p < 0.001). Conversely, post-stroke paretic-leg rotary stiffness mechanisms increased by 37–50% with zero-stiffness exoskeletons. While unimpaired CoM dynamics appear robust to passive ankle exoskeletons, how neurological injuries alter exoskeleton impacts on CoM dynamics merits further investigation. Our findings support Hybrid-SINDy’s potential to discover mechanisms describing individual-specific CoM dynamics with assistive devices.
