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How Accurate are 3D Printed Dental Models?

3D printing and scanning technologies are digitizing dentistry. Instead of the old-fashioned way of taking impressions for things like braces and retainers, which would involve subjecting a patient to biting down on a mouthful of foul-tasting goo, more and more dentists and orthodontists are scanning their patients’ dental anatomy instead. Those scans are then used to 3D print dental models. This is not only easier on the patient, but it’s faster. While many dental offices are sending their digital files to laboratories to have them 3D printed, there is also a growing number of offices that have their own 3D printers, meaning that they can instantly print out the models while patients wait.

How accurate are these models, though? That’s the question that a group of University of Oklahoma researchers asks in a paper entitled “Accuracy of 3-dimensional printed dental models reconstructed from digital intraoral impressions.“

“A rapidly advancing digital technology in orthodontics is 3-dimensional (3D) modeling and printing, prompting a transition from a more traditional clinical workflow toward an almost exclusively digital format,” the researchers state. “There is limited literature on the accuracy of the 3D printed dental models. The aim of this study was to assess the accuracy of 2 types of 3D printing techniques.”

Those two types of 3D printing techniques were digital light processing (DLP) and PolyJet. For the study, the researchers took both digital and traditional alginate impressions from 30 patients. The digital impressions were used to 3D print models using both DLP and PolyJet printing techniques, and the alginate impressions were poured in stone. Measurements for the three model types (digital, DLP and Polyjet) were compared with the stone models.

Tooth measurements (first molar to first molar) included mesiodistal (crown width) and incisal/occlusal-gingival (crown height). Arch measurements included arch depth and intercanine and intermolar widths. Intraobserver reliability of the repeated measurement error was assessed using intraclass correlation coefficients.

“The intraclass correlation coefficients were high for all recorded measurements, indicating that all measurements on all model types were highly reproducible,” the researchers state. “There were high degrees of agreement between all sets of models and all measurements, with the exception of the crown height measurements between the stone and DLP models, where the mean difference was statistically significant.”

The researchers conclude, therefore, that digital impressions and 3D printed models are perfectly viable for clinical applications. This isn’t a surprising conclusion; the accuracy and precision of scanning technology and 3D printing has been heralded by many. This study, however, gives scientific backing to the many claims that are out there. This should encourage many dental professionals that may be hesitant about turning to 3D printing to give the technology a chance; their patients will likely greatly appreciate it, and the results will be just as effective – if not more so – than the less-comfortable traditional techniques.

Authors of the paper include Gregory B. Brown, G. Fräns Currier, Onur Kadioglu and J. Peter Kierl.

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Register by November 8th and Save 38% for Additive Manufacturing Strategies

This January a new kind of 3D printing event will take place in Boston. Additive Manufacturing Strategies is a peer-driven small-scale event that will focus on 3D printing for medical and dental professionals. With such a tight focus you can come while being surrounded by people from your industry and your specialization. Speakers will also be specialized in either medical or dental 3D printing. You will be divided into two groups and surrounded by your peers the focus will be on learning. The Additive Manufacturing Strategies events are meant to let professionals delve deeper into using 3D printing for their businesses. When can 3D printing be used effectively? Where can it be used? In what cases can it not be used? Learning straight from the professionals is what the Additive Manufacturing Strategies events are all about.

Additionally sponsors Trumpf will showcase their Metal Additive Manufacturing technologies for dental and medical applications. Structo will introduce its three dental 3D printers and dental resins specially made for the dental market. Additive Orthopaedics will give us a look at their hammertoe and bunion system as well as its wedge systems. Arfona will show us its desktop 3D printer for dental and special dental materials.

Join your colleagues and other professionals taking the plunge into 3D printing. Register today to not miss the discount.

::vtol::’s Cybernetic Installation umbilical digital #ArtTuesday

::vtol::’s newest piece is incredible, as always. From vtol.cc:

“Umbilical digital” project is a kind of farm where special algorithm that runs on arduino board “cares about” digital nurslings – Japanese Tamagotchi toys that became in due time one of the first pet simulators. Viewing condition of every nursling, the system performs all the necessary manipulations to support “life” and “good spirit” of digital animals. Through simulation of pressing the buttons, the system behaves like an ideal careful host, and a pet exists as if it was nursed by a human.

Looking at the behavior of “organisms”, the algorithm constantly learns and modifies itself. Stats of all processes in real time are shown on a small thermal printer that keeps “chronicle” of the farm that lets retrace the history of colony and its evolution.

Chew on This! Wacker CAPIVA Lets You 3D Print Gum in any Shape

Chewing gum is a treat most of us have enjoyed since childhood with little thought to how it is made or what it is made of, but as so much is changing today due to progressive technology like 3D printing—those interested in making a variety of different edibles can have more creative control over both manufacturing and ingredients. More conventional extrusion processes have produced gum in the past, responsible for the typical shapes we are used to such as strips and small flattened rectangles, or delicious sugary cubes.

Now, Wacker—an international manufacturer and supplier of materials—is opening up a new world of chewing gum production to everyone, with CAPIVA, offering a range of different applications for chewing gum that can be 3D printed.

“Names, logos or lifelike miniature figurines… From now on, chewing gum can be formed in a variety of customizable shapes. WACKER has developed a novel product formulation specifically for printable gum, with software and hardware optimized for this sophisticated food matrix. This new technology prints gum in a wide range of colors, shapes and flavors – individually personalized,” states WACKER.

As with so many new materials accompanying the world of 3D printing today, CAPIVA allows for more simplicity and speed in production, along with offering users and other manufacturers around the world the opportunity to make products that may not have been possible previously.

Their gum base not only means you can 3D print gum and do so efficiently, but these materials allow for better performance and even flavor is improved, with less of an ‘off-taste,’ according to the WACKER team. There is less ‘stickiness’ in the overall product, and WACKER states that their product has been approved in ‘North America, EMEA and many APAC countries including China.’

The CAPIVA line offers everything from pre-mix to resins that enhance gum further—also meant to accompany Wacker’s other chewing gum resins like VINNAPAS, offered for over 60 years. The premix residue is easily removed from machinery and works with a variety of different molds such as starch powder, silicone, and different plastics. You can create an infinite number of shapes for your chewing gum, and the product can be used with most normal candy making machinery too. The products are also compatible with sugar-free processes as well as those that are water or fat based. There is much greater latitude available in the types of flavoring you can choose for your high-tech chewing gum too.

In 3D printing such chewing gum products, amazing detail can be created as you can see in the video below featuring tiny elephant shapes being made—even allowing for the elephant’s trunk to be created in detail. The process is fascinating to watch, and like the rest of us, you may find yourself hankering for some gum to chew!

You can find out more about WACKER here, along with reading about all their products and downloading detailed product sheets. What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

[Source / Images: WACKER]

3D Lab Reveals Affordable Metal Powder Atomizer, the ATO Lab

Formnext, which is coming up next week, is always a setting for big announcements and product reveals. Last year, Polish company 3D Lab presented its first original machine – the ATO One, the first metal powder atomizer working in a laboratory standard. 3D Lab had been around for a decade but had until then been a service bureau and retailer of 3D Systems 3D printers, so the introduction of its first machine was a big deal. Since introducing the ATO One, 3D Lab has received several pre-orders and has spent the past year perfecting the machine, and now as this year’s formnext rolls around the company is preparing to unveil the final version of the product: the ATO Lab.

According to 3D Lab, the ATO Lab is the first compact machine of its kind capable of atomizing small amounts of metal powders. It was designed for research on new materials, but has a number of other applications as well. Other metal atomizers on the market cost well over $1 million, but ATO Lab costs a fraction of this amount and can be easily installed in any office or laboratory.

ATO Lab utilizes an ultrasonic atomization technology that allows for spherical particles with a diameter of 20 to 100 μm. The process is carried out in a shielding gas atmosphere. ATO Lab is capable of atomizing several materials, including aluminum, titanium, stainless steel and precious metals. The machine is also easy to use, the company states, with a user-friendly software system and a touch screen. The user has control over several process parameters.

ATO Lab’s advantages include its ability to atomize a wide range of materials at a relatively low production cost, with no restrictions on the minimum amount of powder being prepared. It’s a scalable system that imparts flexibility to the manufacturing process and allows easy access to material processing for small and medium-sized enterprises.

3D Lab began researching atomization three years ago. The company wanted to rapidly produce small quantities of feedstock for metal additive manufacturing research and process parameters selection. The team found the range of commercially available powders very limited and limiting, and the long realization time of smaller orders and high raw material costs made it impossible to implement a cost-effective solution using currently available atomisation methods.

In addition to the finalization of the ATO Lab, 3D Lab also announced that the Polish venture capital company Altamira invested 6.6 million PLN ($1.8 million) to develop the atomizer manufacturing plant and to build a global distribution channel. 3D Lab also recently moved to a brand new facility in Warsaw. The first ATO Lab devices are expected to be shipped in the first quarter of 2019.

Formnext will be taking place in Frankfurt, Germany from November 13th to November 16th. 3D Lab will be demonstrating the ATO Lab live for the first time; if you will be attending the show you can visit the company and see the atomizer in action in Hall 3.0 at Booth G-20.

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[Images: 3D Lab]

Researchers Test Two Configurations of Biowaste 3D Printed Microbial Fuel Cells

Researchers and scientists are constantly working to develop solutions that can save our future world, from solving problems like increasing pollution and climate change to producing clean energy. A group of researchers from the University of Naples Parthenope recently published a paper, titled “Development and Performance analysis of Biowaste based Microbial Fuel Cells fabricated employing Additive Manufacturing technologies,” about their efforts to test two different configurations of microbial fuel cells (MFCs): bio-electrochemical devices which can directly produce power by converting stored energy into a substrate. MFCs have this unique capability thanks to electrogenic bacteria that can produce and transfer electrons to an electrode with which they are already in contact.

The abstract reads, “In this work two different configurations of MFCs are tested, evaluating the importance of the operative conditions on power production. All the MFCs were fabricated employing 3D printing technologies and, by using biocompatible materials as for the body as for the electrodes, are analyzed the point of strength and development needed at the state of the art for this particular application. Power productions and stability in terms of energy production are deepen investigated for both the systems in order to quantify how much power can be extracted from the bacteria when a load is fixed for long time.”

Reactor Design.

The three main transfer mechanisms are electron shuttles, conductive nanowires, and redox reactions between bacteria and the electrode. Scaling up for real MFC applications would be expensive, as the needed materials, like NafionR and platinum, are costly. But 3D printing can be used to help lower costs, as well as offer more stable energy production.

“Due to that a more sustainable and less wasteful production can be applied to MFCs bioreactors. In addition, materials suitable for 3D printing are moving to bio-based solutions completely recyclable that would strength the sustainability by closing the loop also for the materials,” the researchers wrote.

For their study, the team investigated and tested two kinds of reactors: single chamber and double chamber. The biggest difference between them regards the use, or lack thereof, of a chamber for locating the cathode electrode.

Exploded and Compact view of (A) Single Chamber MFC, (B) Double Chamber MFC.

“In the reactors design the distances between cathodes and anodes in both layouts is fixed to 2 cm,” the researchers explained.

“In the single chamber configuration, activated carbon coated with PTFE and a nickel mesh as current collector are used as cathode (7 cm2 as active surface area) and a PLA based material is used for realizing the anode (9.7 cm2 active surface area).

“In the double chamber reactor, both electrodes (cathode and anode) are realized by using the PLA based material like that used for the anode of the single chamber reactor. These electrodes have also the same shape (9.7 cm2 active surface area). Moreover, a cation exchange membrane (CEM) is used as medium between the two chambers.”

Open source Free CAD was used to design the cube-shaped reactors, which included an internal circular hole for extra volume, and a Delta Wasp 20 40 3D printer fabricated the reactors out of non-toxic, conductive PLA from Proto-pasta.

The researchers noted, “This material is suitable for the application in MFC, but improvements are needed in order to obtain better power production.”

The team used bacteria from a mixture of compost taken from an Italian waste treatment facility and household vegetable waste for their experiments, and left the 3D printed reactors in a temperature-controlled environment of 20°C for 48 hours before beginning acquisitions.

“An experimental data acquisition system, is used to record the performances of the MFCs, consisting of an embedded system controlled by an Arduino board connected to sensors that recorded voltage and current at each operative condition set. The DAQ, with a sample frequency of 0.1 Hz (10 s), is able to switch automatically the resistance applied at the ends of the electrodes in order to easily obtain polarization curves. In particular, polarization procedure consists in the application of four different resistance (36000-27000-12000-8000 W) for 5 minutes each,” the researchers wrote.

“The procedure is continuous, so the total time needed is 20 minutes. Finally, the value of resistance that gives the maximum power is applied for four hours in order to test how the response of the same to an extended load.”

Conductive PLA Electrode Design.

The researchers continuously recorded the MFCs’ Open Circuit Voltage (OCV), and the double chamber system showed a higher starting potential of 0.95 V compared to the 0.59 V of the single chamber system. They noted a “great stability” during their experimental tests, and determined that 3D printing is “a suitable technology for the fabrication of the MFC in terms of precision and costs.”

“Results of the experiment show that both configurations are affected by a high internal resistance and, as a consequence, a limited power production has been achieved. As expected, better results are registered for the double chamber, mainly due to the use of CEM and the presence of potassium permanganate at the cathode that, probably, better balanced the redox reactions that occurred,” the team concluded. “However, this difference is very low (+11%) and the reason can be found in the materials used for the electrodes. AC coated with PTFE electrode (1 W resistance), used as cathode in the first configuration, allows better performance than the conductive PLA (400 W resistance approximately).”

Co-authors of the paper are Elio Jannelli, Pasquale Di Trolio, Fabio Flagiello, and Mariagiovanna Minutillo.

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Scientists 3D Print an Effective Terahertz Waveguide

(a) Segments of the hollow waveguide; (b) experimental results of the loss coefficient; (c) mechanical spliced 90 cm hollow waveguide.

The terahertz (THz) wave is the electromagnetic radiation at frequencies from 0.1 to 10 THz, which is located between the millimeter wave and the far infrared wave. It has not been fully studied because of a lack of effective means of generation, detection and transmission, so it is referred to as the “Terahertz Gap.” The terahertz wave has a lot of potential in non-destructive imaging, biomedicine and national security and defense, because it has penetrability for most of non-polar materials and does not cause ionization damage while covering the vibration and rotational energy levels of biological macromolecules.

In a paper entitled “A 0.1 THz low-loss 3D printed hollow waveguide,” a group of researchers discusses the use of 3D printing to create THz functional devices, such as terahertz lenses, phase plates, waveguides and more. 3D printing is a low-cost, simple and effective way to create these devices, they point out.

“Therefore, the combination of low-loss dielectric waveguide and low-cost 3D printing will help to break through the bottlenecks and realize THz remote applications,” the researchers state. “The paper focuses on the design, fabrication, and characterization of a novel 0.1 THz low-loss hollow waveguide. Its theoretical loss is as low as 0.009 cm−1 and the measured loss is 0.015 cm−1. The experimental results show that the proposed hollow waveguide not only reduces the transmission loss of the terahertz wave, but also can effectively localize the terahertz field and confine the divergence angle of the terahertz beam.”

The researchers used PLA to create the hollow waveguide. First they needed to 3D print a PLA disk in order to obtain the elecrtromagnetic parameters of the material. The disk was printed on an Ultimaker 3D printer and characterized by terahertz time-domain spectroscopy (THz-TDS).

“After that the design for the hollow waveguide could be started,” the researchers continue. The first step is designing the cross section of the waveguide based on the anti-resonant waveguide model and drawing the cross section’s two-dimensional graph. Secondly, the graph is imported into the finite element simulation software (Comsol Multiphysics) and a larger circle around the cross section is drawn as the perfect matching layer. Thirdly, the different materials and the corresponding refractive index are selected and the design model is meshed. Finally, according to the simulation, the effective refractive index of different modes transmitted in the center air hole of the hollow waveguide can be acquired.”

(a) Cross section of the hollow waveguide; (b) HE11 fundamental mode field distribution

The 90-cm-long hollow waveguide was then 3D printed and characterized. To verify the localization effect of the hollow waveguide on THz wave, the researchers measured the THz divergence angle at the end of the waveguide. The measured loss was 0.015 cm−1. The experimental results showed that the hollow waveguide can not only reduce the transmission loss of the terahertz wave in the air, but also effectively localize the terahertz wave. The researchers conclude that remote low-cost THz sensing and imaging can be achieved in the future by the development of flexible and longer hollow waveguides.

Authors of the paper include Pengfei Qi, Weiwei Liu and Cheng Gong.

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MetalMaker 3D Launching Rapid Prototyping Service for Metal 3D Printed Parts On Demand

Tomorrow, North America’s largest metal forming, fabricating, welding, and finishing event, FABTECH, will begin at the Georgia World Congress Center in Atlanta. Many industry announcements will be made at the trade show, including one from advanced manufacturing startup MetalMaker 3D. The Connecticut-based company has just launched its new rapid prototyping service for on-demand 3D printing of metal parts. The process, which integrates investment casting with 3D printing, is said to be a more practical alternative to direct metal laser sintering, or DMLS, 3D printing.

“Until now, there has been a clear divide between the promise of metal additive manufacturing and reality of the types of metal parts that can practically be used in industry,” Eric Sammut, the CEO of MetalMaker 3D, told 3DPrint.com. “We are bridging that gap and offering a solution that maintains the performance of traditional manufacturing while delivering on the promise of additive manufacturing.”

Backed by seed accelerator Techstars and Stanley Black & Decker, MetalMaker 3D offers an industry-compatible solution for 3D printing metal parts that addresses many limitations of DMLS. Because parts made with DMLS 3D printing don’t have the same material properties as traditionally manufactured components, they are often also too expensive to use for the purposes of prototyping. But, MetalMaker 3D claims that it can offer truly isotropic metal parts, which are up to ten times cheaper than parts made with DMLS, with just one week of lead time.

Sammut explained, “Our goal is to enable manufacturers to use this additive pattern investment casting process in-house to produce custom metal parts in less than 24 hours.

“By combining additive manufacturing with investment casting, we get the best of both worlds: the design freedom, customizability, and rapid iteration of additive, along with the consistent mechanical, dimensional, and material properties of metal casting.”

The startup’s process can make functional metal parts with the design freedom inherent to 3D printing, while also providing the “isotropic mechanical and dimensional properties” that occur with high precision casting.

Currently, MetalMaker 3D is developing small-scale foundry systems for in-house investment casting so manufacturers can use the process for prototyping and low-volume production of complex metal parts, and is already working with several manufacturers, including partner Stanley, on real-world case studies. But, at FABTECH tomorrow, the startup will officially launch its rapid prototyping service, which involves working closely with its manufacturing customers to “refine their commercial product offering.”

While MetalMaker 3D does plan to expand its range of material options in the future, it will begin by offering rapid prototyping for aluminum parts with the aluminum 356 casting alloy – one of the most widely used in both the aerospace and automotive industries. In addition, the startup will also be offering optional T6 heat treatments as part of its new prototyping service.

Sammut said, “We can match the alloy, process, and heat treatment to create functional metal parts that are indistinguishable from commercially manufactured components.”

MetalMaker 3D will be running its prototyping service at the same time it works to continue developing its product offering, so its manufacturing customers can complete the process in-house. To request quotes and order custom 3D printed metal parts through the startup’s new on-demand rapid prototyping service, just fill out the quote form to receive a response within 48 hours…once FABTECH is over, of course.

If you will be attending the trade show in Georgia this week, visit MetalMaker 3D at Booth B5642 in the Additive Pavilion.

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Toward Better 3D Printers: A New Test From Autodesk and Kickstarter

Kickstarter has announced, in collaboration with Autodesk are addressing a challenge that Kickstarter creators and backers face: lack of a common standard to assess the performance of FDM 3D printers. (Fused Deposition Modeling is the standard layer-by-layer process that you’ve probably seen even if you’ve only encountered a few 3D printers.)

Kickstarter, with generous help from Autodesk, is releasing a new open-source printing test for Kickstarter creators.

Autodesk research scientist Andreas Bastian has developed a test procedure designed to help creators better calibrate their machines and showcase their printers’ capabilities to backers on Kickstarter. He developed a single, consolidated STL file that tests a printer’s dimensional accuracy, resolution, and alignment. For example, poor execution of the “bridging” feature shown below will lead to a saggy and stringy print. A well-calibrated printer will make the horizontal feature with fewer of those issues.

See the entire post here on the Kickstarter blog.

3D Printed Models Help Students Gain a Better Understanding of DNA Behavior

In a paper entitled “Visualizing the Invisible: A Guide to Designing, Printing and Incorporating Dynamic 3D Molecular Models to Teach Structure-Function Relationships,” a group of researchers from the University of Nebraska discusses the importance of using three-dimensional models to help students understand critical biology and chemistry concepts. Teachers, the researchers point out, often rely on two-dimensional images to teach complex three-dimensional concepts, such as the structure of molecules, but students cannot fully grasp the concepts using only 2D images. Kits with 3D models exist for teaching purposes, but they “cannot handle the size and details of macromolecules.”

3D printing, however, allows instructors to create detailed custom models of molecules of any size.

“For example, protein models can be designed to relate enzyme active site structures to kinetic activity,” the researchers state. “Furthermore, instructors can use diverse printing materials and accessories to demonstrate molecular properties, dynamics, and interactions.”

In the paper, the researchers describe the creation of a 3D model-based lesson on DNA supercoiling for an undergraduate biology classroom. They selected this particular model so that students could “feel DNA relaxation and witness contortions resulting from twists in DNA.” They designed and 3D printed flexible plastic models with magnetic ends to mimic DNA supercoiling.

“We developed a Qualtrics-based interactive activity to help students use the models to classify supercoiled DNA, predict the effects of DNA wrapping around nucleosomes, and differentiate between topoisomerase activities,” the researchers explain.

An upper-level undergraduate biochemistry class was divided into small groups of two to three students to foster peer learning, and each group was provided with one model set. The models were also made available at a library resource center. Interactive questions required the students to measure and explore physical aspects of the models. It took the students about 50 minutes to complete the activity, which was interspersed with lecture and demonstration via a digital overhead.

In interviews following the activity, the students reported that the models helped them learn because “physically seeing it makes something abstract very real.” In a survey, 60 to 70 percent of students stated that the physical models made it easier to learn the material being taught.

The researchers go on to provide step by step instructions for creating 3D printed models for use in the classroom. They designed the models around student misconceptions, they explain, and the models were shown to be effective in clearing up those misconceptions. This study reaffirms what many researchers and educational professionals have learned – that 3D printed models are an excellent way to teach students of any age group. From preschoolers learning shapes and textures to college students learning about DNA supercoiling, having hands-on models helps to make concepts real and accessible. 3D printing is a cost-effective way to create those models, and it is capable of presenting detail in a way that other fabrication methods are not.

“Three-dimensional printing represents an emerging technology with significant potential to advance life-science education by allowing students to physically explore macromolecular structure-function relationships and observe molecular dynamics and interactions,” the researchers conclude. “As this technology develops, the cost, resolution, strength, material options, and convenience of 3DP will improve, making 3D models an even more accessible teaching tool.”

Authors of the paper include Michelle E. Howell, Karin van Dijk, Christine S. Booth, Tomáš Helikar, Brian A. Couch and Rebecca L. Roston.

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