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Abstract Additive manufacturing technologies have the potential to revolutionize the manufacturing industry by making it easier to fabricate complex structures, high value, and low volume parts in various contexts. Bio-additive manufacturing is particularly promising, as it has enabled the 3D printing of human organs. Researchers have made progress by developing novel materials and printing strategies for additively manufacturing complicated mission-critical geometries. On the other hand, assessing the structural integrity of these bio-printed structures has been challenging, as destructive contact-based approaches may interfere with the manufacturing process and affect the original dynamics and quality of the bio-prints, due to the relatively soft and lightweight nature of bio-prints. Furthermore, the repeatability of measurement is significantly dependent on the quality of how the sensor is attached to the part. Non-contact methods, such as laser and X-ray based techniques, can provide measurements without adding mass to the part. However, lasers may produce inaccuracies due to reflection and absorption in translucent materials, which are often found in bio-constructs. Although there have been significant advances in non-contact methods for reliably identifying damages in bio-printed structures, particularly embedded defects, implementing these approaches in a straightforward way has been challenging. To advance the state-of-the-art, this study proposes a novel method that can reliably assess the damage properties without contact by using video-based vibrometry. Vibration signals can provide a comprehensive response of the target structure, including material properties and geometry changes due to embedded defects in bioprinting. By analyzing the phase shift of the pixel intensity in the video, the vibration characteristics that indicate surface and/or embedded defects can be assessed for the entire structure captured in the camera angle, without the need for multiple sensors to be installed on the structure. This research focuses on analyzing the vibration characteristics of a cube that was manufactured by an extrusion-based bio-printer with pneumatic dispensing using sodium alginate based bioink. A high-speed camera and phase-based motion estimation technique are used to obtain experimental data on the vibration characteristics of the cube. Volumetric defects introduced by extrusion pressure irregularity and scaffolds with voids and their severities are identified by monitoring the vibration characteristics. These findings suggest that the proposed method could be utilized to effectively verify the structural integrity of additively manufactured organs during fabrication, which could enhance process optimization and operation safety. Future works include incorporating finite element model to compare its response characteristics for healthy and damaged models with the experimentally obtained results and identifying the detection sensitivity and limit with respect to parameters such as damage type and location.
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Nozzle Pressure Defect Detection in Extrusion-Based Bio 3D Printing Using Video-Based Motion Estimation
The emergence of bio-additive manufacturing marks a crucial advancement in the field of biomedical engineering. For successful biomedical applications including bioprinted organ transplants, ensuring the quality of printed structures poses a significant challenge. Among the major challenges encountered in ensuring the structural integrity of bioprinting, nozzle clogging stands out as one of the frequent concerns in the process. It disrupts the uniform distribution of extrusion pressure, leading to the formation of defective structures. This study focused on detecting defects arising from the irregularities in extrusion pressure. To address this concern, a video-based motion estimation technique, which emerged as a novel non-contact and non-destructive technique for assessing bio 3D printed structures, is employed in this research. While other advancements, including contact-based and laser-based approaches, may offer limited performance due to the soft, lightweight, and translucent nature of bioconstructs. In this study, defective and non-defective ear models are additively manufactured by an extrusion-based bioprinter with pneumatic dispensing. Extrusion pressure was strategically controlled to introduce defective bioprints similar to those caused by nozzle malfunctions. The vibration characteristics of the ear structures are captured by a high-speed camera and analyzed using phase-based motion estimation approaches. In addition to ambient excitations from the printing process, acoustic excitations from a subwoofer are employed to assess its impact on print quality. The increase in extrusion pressure, simulating clogged nozzle issues, resulted in significant changes in the vibration characteristics, including shifts in the resonance frequencies. By monitoring these modal property changes, defective bioconstructs could be reliably determined. These findings suggest that the proposed approach could effectively verify the structural integrity of additively manufactured bioconstructs. Implementing this method along with the real time defect detection technique will significantly enhance the structural integrity of additively manufactured bioconstructs and ultimately improve the production of healthy artificial organs, potentially saving countless lives.
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- Award ID(s):
- 2301948
- PAR ID:
- 10618032
- Publisher / Repository:
- American Society of Mechanical Engineers
- Date Published:
- ISBN:
- 978-0-7918-8832-2
- Format(s):
- Medium: X
- Location:
- Atlanta, Georgia, USA
- Sponsoring Org:
- National Science Foundation
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- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Conference Paper:
- https://doi.org/10.1115/SMASIS2024-140392
