PEAK Launches Alien Beast 3D Printed Shoes for Limited Sale

In the fashion world, we have seen everything from haute couture collections to custom jewelry lines. Shoes of all kinds have been produced too, and usually tend to offer an interesting story—whether futuristic athletic shoes are being customized for runners, or designers are 3D printing elegant ballet flats or outrageous looking high heels.

Now comes the latest in casual cool from PEAK, an international company headquartered in China, known for its extensive sports products. The ‘Alien Beast’ is a new pair of shoes just released by PEAK, and they do have an enticing look—not to mention that edgy name! And while often marketing may be what it’s all about in the fashion and footwear realm, they have continued to refine their development of sneakers (check out their unique basketball and volleyball shoes launched over the past few years).

With the Alien Beast model, PEAK designers embraced the classic “art imitating nature” technique, invoking the influence of exotic animals from China. The design is both striking and alluring due to the sharp edges and corners, and stark lines.

With a detailed design, PEAK meant to imitate both bone spurs and scales, melding a wing shape onto the heel to complement the upper portion—suggesting the opportunity for flight, as well as that of a dragon’s face staring at you. Bringing the designs to life with bionics and integrated into one piece—rather than “spliced” into sections, the goal of the team at PEAK was to create a smooth look, while offering comfort to the consumer. Even with their beastly name, the 3D printed shoes are somewhat delicate, featuring a smooth texture and anti-skid soles.

Overall, the PEAK collection targets consumers engaged in running, tennis, basketball, and football. They offer a wide range of products which are manufactured conventionally but continue to move toward fully 3D printed products. This has been a trend for a smattering of footwear manufacturers, to include some major players like Adidas—ambitiously planning for mass 3D printing automation, only to kill off some of their Speedfactories last year. As other companies like PEAK continue to be optimistic about 3D printing in footwear (in small volume so far), only time will tell whether it is a novelty or truly a technology that can be integrated into and transform this type of manufacturing.

PEAK was founded in 1989 and operates a network of 6,000 stores around the world dedicated to sales of shoes, sports clothing, and accessories. They have also been very involved with athletes worldwide—from medal-winning Olympians to basketball players and soccer players.

Alien Beast footwear went on sale August 12th in Beijing, with only a limited amount of 299 pairs available for sale.

[Source / Images: Tencent]

The post PEAK Launches Alien Beast 3D Printed Shoes for Limited Sale appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Farsoon Releases Flight 252 High Temperature 3D Printing Platform

Following the progress of many manufacturers over the years, it is clear that users around the globe are not left wanting for the new technology and new resources required to keep reaching for the stars while innovating. China’s Farsoon Technologies (with headquarters also in the US and Germany) is a dynamic example of this system—within an industry worth billions—continuing to serve customers with new printers, platforms, and materials within the additive manufacturing space.

Now, Farsoon moves further forward with its Flight Technology (initially unveiled at TCT Asia 2019) for the compact Flight 252P platform. Two new plastic powders are also being released, and Farsoon claims they will not only improve performance in parts, but also savings on the bottom line. With over 25 years in the industry, Farsoon is a pioneer in the plastic laser sintering solutions market and its team expects to continue pushing forward in terms of enhancing efficiency in production, performance, and expansion.

Notably, these new products are being announced at TCT Asia 2020, running from July 8-10. This is the “first physical trade show” the Farsoon team will be attending since the COVID-19 viral pandemic forced show cancellations around the world. Visitors will be able to check out the new platform in person now, finding out more about high-temperature printing, reaching from 220°C (HT) to 280°C (ST). Other features of the new system include better thermal control, improved parameters, and temperature-shielded components.

The 252P is smaller, making it suitable for laboratories as well as onsite for small-scale production. This new platform also provides industrial users with the opportunity to use a wider range of materials. In comparison to typical laser sintering systems, Farsoon also promises that the Flight 252P offers more latitude for developers in terms of materials and applications. Comprehensive processing is offered, and along with a smaller laser spot size (and better laser longevity) comes “greatly increased power.”

The new materials offer the following:

  • PA12 based FS3201PA-F powder for Flight Technology – for applications like auto, electronics, and consumer markets, this advanced formula is meant to offer better durability and reusability.
  • FS2300PA-F polyamide powder is meant to offer users better affordability, faster production, as well as “excellent plasticity.”

Farsoon continues to be known for its advances in additive manufacturing, collaborations with other global leaders, and sales of large installations of hardware.  Are you interested in joining the Farsoon early adopter program? If so, contact globalinfo@farsoon.com for more information.

[Source / Images: Farsoon]

The post Farsoon Releases Flight 252 High Temperature 3D Printing Platform appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Comparing 3D-Printed and Traditional Guide Plates for Placing Orthodontic Brackets

The most important part of orthodontic treatment is the correct positioning and bonding of the brackets. Direct bonding is less accurate and often takes longer due to saliva and inaccessible tooth positions, while indirect bonding is quicker and less likely to cause bracket positioning errors, but is costlier. A team of researchers from Beijing published a paper, “Comparison of three-dimensional printing guides and double-layer guide plates in accurate bracket placement,” where they designed different types of transfer trays, using 3D printing and traditional impressions, and evaluated their “clinical efficacy.”

“With the increasing applications of indirect bonding, various designs of transfer trays and novel technologies are implemented in the treatment procedure. In the laboratory stage, the patients’ occlusal interrelationship can be duplicated either by impression or digital scanning,” the researchers wrote. “The former is a traditional method to generate double-layer guide plates; though with a lower cost, this method typically takes longer laboratory time and is susceptible to human errors. The latter is incorporated with cutting-edge 3D printing technology that provides various advantages, such as precise 3D images, convenience in file storage, and accuracy in image analysis and outcome prediction [5].”

The study model. (a) Maxillary model with marking points. (b) Mandibular model with marking points.

In the laboratory stage of indirect bonding, brackets are bonded to the patient’s orthodontic model, and then a customized transfer tray is used to place them on the actual surface of the tooth in the clinical stage. To make the models for this study, the team collected 140 teeth with normal crown morphology and no evident defects or restorations, sterilized them, and arranged them into “five pairs of full dentition” before labeling the marking points “on the buccal/labial surface of the crown.”

Digital design and 3D printing guides. (a) Distinguishing teeth and gingiva on the digital models. (b) Establishing the occlusal plane. (c) Adjusting the bracket positioning. (d) Simulation of bracket positioning. (e-f) Guide plate for indirect bonding on digital models. (g) 3D printing guide – whole denture type, and (h) single tooth type.

Next, they created 3D printable indirect bonding guide plates, beginning by generating digital models with the 3Shape TRIOS Standard intraoral scanner. The occlusal plane, axis, and center of individual crowns were established, and the marginal gingiva labeled, using 3Shape software, and guide plates for the whole denture type and single tooth type for 3D printed on a ProJet 3510 DP.

“The brackets were positioned in the 3D printing guides (the whole denture type or the single tooth type), and 3 M Unitek Transbond™ XT light-curable adhesives were applied to the base of the brackets,” the team explained about the indirect bonding procedure. “The 3D printing guides were then placed on the study models, and each border of the brackets was light-cured for 5 s.”

3D printing guides and indirect bonding procedure. 3D printing guide of the (a) maxillary and (b) mandibular dentitions. 3D printing guides placed on the (c) maxillary and (d) mandibular study models. Completion of bracket positioning on the (e) maxillary and (f) mandibular study models.

In making the traditional trays, the researchers used silicone-based materials to get impressions of the working models with intact marking points, and created plaster casts from the silicone molds.

“A thin layer of separation agents was applied to the cast tooth surfaces; then, the brackets were positioned and adhered on the crowns using 3 M Transbond™ XT light-curable adhesives and light-cured for 5 min,” they wrote. “Double-layer guide plates were manufactured by Erkoform-3D Thermoformer with a 1 mm inner layer (soft film) and 0.6 mm or 0.8 mm outer layer (hard film). Lastly, we trimmed the excess materials of the inner layer to 2 mm above the crowns and the outer layer until covering 2/3 of the brackets.”

The impression of (a) maxillary and (b) mandibular dentitions, and the plaster casts of (c) maxillary and (d) mandibular dentitions.

Bracket positioning on the (a-c) maxillary and (d-f) mandibular dentitions. Double-layer guide plate of the (g) maxillary and (h) mandibular dentitions.

For this indirect bonding procedure, the bracket were placed in the double-layer guide plates, with one solution applied to the surfaces of the teeth and another to the bracket base. Then, the guide plates were put on the study models, and after two minutes of fixation, the researchers removed the outer hard layer first, and then the inner soft layer.

Double-layer guide plates placed on the (a-c) maxillary and (d-f) mandibular study models. Completion of bracket positioning on the (g-i) maxillary and (j-l) mandibular study models.

Next, Materialise Mimics software was used to measure the distance between the marking points and bracket positions in the digital models of both the whole denture and single tooth designs for the 3D printed guide group, while electronic calipers measured the distance in the study models.

Electronic caliper.

Marking points on the plaster cast and study model.

SPSS software was used to analyze the distance.

“The accuracy of indirect bonding between 3D printing guide and double-layer guide plate was compared using the paired t-test. P < 0.05 indicated statistical significance,” they explained.

The data, reflected in the tables below, showed that there was no statistical difference in the accuracy of bracket positioning between the two types (p = 0.078), and that the 0.6 mm type in the double-layer guide group had much better results (p = 0.036) than the 0.8 mm one.

“We then further compared the accuracy of indirect bonding between 3D printing guides (whole denture type) and double-layer guide plates (0.6 mm), the results were comparable between two groups (P = 0.069),” they wrote. “However, indirect bonding using double-layer guide plates (0.6 mm) cost less chair-side time than the 3D printing guides group.”

Table 1: Comparison of different designs in 3D printing guide group.

Table 2: Comparison of different designs in double-layer guide plate group.

Table 3: Comparison of bracket positioning accuracy between 3D printing guide and double-layer guide plate.

However, while the data showed no statistical significance, the researchers noted that “the overall discrepancy before and after bracket transfer was lower in the 3D printing guides group.”

“This finding might be due to our in vitro study models with only mild malocclusion,” they explained. “Further in vivo studies in more severe clinical cases, such as malocclusion with torsion/tilting/overlapping, will be essential to investigate the efficacy and generalizability of 3D printing guides and double-layer guide plates.”

Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts below.

The post Comparing 3D-Printed and Traditional Guide Plates for Placing Orthodontic Brackets appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

China: 3D Printed Vertebral Body Used to Reconstruct Upper Cervical Spine of 9 Patients

Primary osseous spinal tumors make up roughly 5% of all primary bone tumors, and reconstruction is required to restore the spine’s integrity and stability. However, it’s hard to reconstruct this complex section, which is responsible for transitioning the axial loading force from the cranium to the spinal column, and subpar implants can result in complications like migration and nonfusion.

3D printing can be used to fabricate patient-specific porous implants for fixing these bone defects. A group of researchers from Beijing published a study, “Upper cervical spine reconstruction using customized 3D-printed vertebral body in 9 patients with primary tumors involving C2,” where they described “the clinical outcomes of upper cervical spine reconstruction using customized 3D-printed vertebral body,” with “a mean follow-up of 28.6 months” for the patients.

“Patients with primary tumors involving C2 who were treated in our institution between July 2014 and November 2018 were enrolled,” the team stated.

“Nine patients (2 males and 7 females) were included in the study with a mean age of 31.4 years (12 to 59 years). Seven patients demonstrated tumors located in C2 and 2 showed involvement of C2 and C3.”

The nine patients initially complained of “aggravating pain,” with two suffering neurological impairment, and average duration since the onset of these symptoms was almost three months. Here’s the tumor breakdown for the patients, established using a CT-guided biopsy:

  • 4 giant cell tumors (GCT)
  • 2 chordoma
  • 1 Ewing sarcoma
  • 1 paraganglioma
  • 1 aggressive hemangioendothelioma

Fig. 1: Imaging studies for patient #3. The achievement of osseointegration was defined when new bone formation was observed around the bone-implant interface on X-ray (B) and CT (D) during the follow-up compared to that of immediately postoperative (A,C). The postoperative segment vertebral height was measured on the midsagittal reconstruction CT from atlas anterior tubercle to the midpoint of the adjacent lower endplate (C).

Making the implants was a 7-day process. First, CT scans were performed on the patients’ spines, and the DICOM data was imported into Materialise Mimics 15.0 software, where a CAD model for the implant was designed. Ti6Al4V powder was used to print the porous metal scaffold implants with Arcam EBM’s electron beam melting technology.

“Based on our previous studies, the parameters set for the trabecular structure and the size of the uniform micro-pores were determined to generate the optimized biomechanical and osteoinductive properties (,,). The upper contact surface morphology of the implant coincided with the inferior articular surfaces of C1, while the lower contact surface morphology coincided with the upper endplate of the caudal vertebra,” they wrote.

Fig. 2: The 3D printed artificial vertebral body with porous scaffold fabricated out of titanium alloy powder.

A two-stage intralesional spondylectomy was performed on each patient, and the 3D printed vertebral body was used to accomplish anterior reconstruction, without the use of a bone graft.

“The average interval between the posterior and anterior procedures was 14.4 days,” the researchers said.

“In the first 4 cases in this series, occipitocervical fixation was performed (Figure 1). Subsequently, with more confidence in the stability of the 3D-printed anterior construct, we were able to preserve the atlanto-occipital joint in the next 5 cases.”

If you’re interested in the rest of the nitty-gritty surgical details, check out the full research paper.

Table 1: The details of the 9 patients

In the table above, you can see the details of the patients, who all had follow-up appointments after the 3D printed vertebral body was implanted. All nine received postoperative radiotherapy, while two also received chemotherapy.

“Patient one died of systemic metastases 15 months postoperatively without signs of local recurrence. Patient seven had tumor local recurrence. The others were alive and functional in their daily livings at the last follow-up without evidence of disease. At their final follow-ups, the neurological status of all alive patients was ASIA E, and the average VAS score was 0.9. Three patients had ECOG 1, while 5 patients had ECOG 0 for their general well-being and activities of daily life,” they stated.

Fig. 3: Imaging studies for patient #3.

Through radiograph and CT examinations, the researchers observed new bone formation around the bone to implant contact surfaces, “which provided the evidence of osseointegration,” and they found that all of the 3D printed vertebral bodies were stable, without any signs of ” implant displacement or subsidence.” Additionally, none of the screws had come loose, and there was no rod breakage in the posterior instrumentation systems.

The researchers found several advantages to using 3D printing for this reconstruction rather than traditional methods of manufacturing, such as the implant offering “reliable primary immediate postoperative stability.” A patient-specific implant provides a better match to bony surfaces and a larger contact area, and because screw tracks are actually integrated directly into the artificial vertebra, “self-stabilization” occurs.

Fig. 4: Imaging studies for patient #6 showing fusion process. Compared to the immediate postoperative X-ray (A) and CT (D), regenerated osseous tissue can be seen to have gradually grown along the implant 12 months (B,E) and 24 months (C,F) post-op (arrow).

“Secondly, the anatomical design of the contact surface of the curved porous endplate and its biocompatibility provided reliable mid-long-term stability. The porous bone-contacting surface of the 3D-printed vertebral body is conducive to bone in-growth into the trabecular pores to achieve firm osseointegration, which was supported by evidence from previous basic research and in vivo studies (,,),” they explained.

Additionally, post-op radiotherapy may not affect the 3D printed vertebral body as much, so long as osseointegration on two ends occur, “because solid combination was accomplished.” Conversely, this treatment can lead to instrumentation failure with conventionally manufactured implants.

“In our study, the progress of osseointegration is evident on follow-up with imaging studies. On lateral radiography, regenerated osseous tissue was seen adhering to the 3D-printed vertebral body (Figures 1B,4B,C1B,4B,C).),” the researchers noted. “Sagittal CT revealed new bone tissue crawling and growing around the ends of the 3D-printed vertebral body from the upper and lower vertebra (Figures 1D,4E,F1D,4E,F).). All patients were capable of resuming normal activity without mechanical pain associated with spinal instability at 12-month follow-up.”

Finally, a 3D printed vertebral body could mean there’s less of a need for transoral (direct access through the mouth) or transmandibular surgical approaches. For example, as noted above, this research team used the posterior-anterior approach to perform C2 spondylectomy, which made it easier and safer to isolate the vertebral arteries.

“Our study suggests that 3D-printed implant may be a good option in upper cervical reconstruction, the tailored shape matching with the contact surfaces and the porous structure conductive to osseointegration provide both short- and long-term stability to the implant,” the researchers concluded. “However, a higher level of evidence is still needed.”

Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts below.

The post China: 3D Printed Vertebral Body Used to Reconstruct Upper Cervical Spine of 9 Patients appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Researchers Evaluate Feasibility of Closing Multiple Atrial Septal Defects Guided by 3D Printed Model

We’ve often seen physicians use 3D printed heart models to help during surgeries, but a group of researchers from China published a paper on using them to help with an alternative to surgery for repairing secundum atrial septal defect (ASD), a rare congenital defect characterized by a hole in the wall between the atria. Their goal was to evaluate how feasible it was to use a single device to close several ASDs guided by the 3D printed heart model and transthoracic echocardiography (TTE).

Due to interference between devices and threat of repeat intervention, it’s difficult to use multiple devices simultaneously, or in staged device closure, in percutaneous transcatheter closure of an ASD. But using an over-sized device, can tear the atrial septum. So the best plan is to use single device closure for patients with multiple ASDs, as it preserves the anatomical structure.

“However, this strategy is technically challenging because of inability to determine the target defect for catheter passage and occluder selection, warranting careful interventional planning with comprehensive anatomical information for successful device closure,” the team wrote.

That’s where the 3D printed heart model comes in. The researchers used the single-device strategy, assisted by 3D printing, to perform multiple ASDs closure, and compared their results of “3D printing-based and transthoracic echocardiography (TTE)-guided percutaneous transcatheter closure with those of traditional fluoroscopy-guided closure.”

Simple working flowchart in patients with multiple ASDs, from image acquisition to 3D printed solid and hollow model.

62 patients diagnosed by TTE with two or more ASDs with a 5mm or more diameter, were enrolled in their non-randomized study for analysis. 30 had cardiac computed tomography angiography (CTA) ahead of surgery in order to get data to create their 3D printed heart models. The CTA images were reconstructed and saved in DICOM format, before being imported to Materialise Mimics software. Cardiac masks were generated for 3D models, and 3-matic software was used to hollow them. The STL files were 3D printed, in hollow fashion, at 1:1 scale on a ProJet MJP 2500 Plus 3D printer out of silicone.

3D printed model of a patient with multiple ASDs. (a) and (b) show the model from left and right atrial sides, respectively. The arrows depict the position of the ASDs. (c) and (d) illustrate the status after occluder deployment in the model.

The surgeons performed in vitro simulated occlusion with the 3D printed models as a pre-op evaluation. Then, while the other 32 patients underwent ASD closure with fluoroscopic guidance, this group had TTE-guided closure procedures.

“The apical four-chamber view and parasternal short-axis view were used for guidance, and the multipurpose catheter was passed through the targeted defect, which was determined using the 3D printing model and intraoperative TTE,” the researchers explained.

“Then, a single septal occluder was inserted for ASD closure under TTE guidance. An ASD occluder or PFO occluder was selected based on the in vitro simulated occlusion in a 3D printing model.”

After implantation, the device position was evaluated through subcostal, apical four-chamber, and parasternal short-axis views, and they also performed Color Doppler assessment to detect any issues, like coronary sinus return or residual shunting. Once they determined that the occluder had been implanted correctly, “it was released by rotating the cable counterclockwise under TTE guidance,” and a reassessment was then performed in echo views, below.

Percutaneous closure of multiple ASDs under TTE guidance. (a) Multiple ASDs image displayed in subcostal view. (b) The left disc was released (parasternal short-axis view). (c) The ASDs were closed (four-chamber view).

“In the conventional group, multiple ASDs occlusion was performed under fluoroscopic guidance using the single occlusion device,” they wrote. “Based on TTE measurements, the single device was selected, equal to or up to 4 mm larger than the main defect [10]. According to experience [102021], the device was usually implanted into the largest defect. The occluder was replaced if echography found more than two residual shunts, the residual shunt was >5 mm in diameter, or the device compressed the mitral valve.”

Immediately post-op, and 6 months after the device closure, all 62 patients were evaluated via TTE and electrocardiogram, with the researchers noting the presence of any arrhythmia, residual shunt, or valve dysfunction. A Brand-Altman analysis was used to evaluate the agreement “between device size of 3D printed model and traditional estimation,” and the data was analyzed with SPSS software.

Bland–Altman plot analysis. Bland–Altman plot of empirical estimation versus 3D printed model estimation of occluder size.

They found that 26 patients in the 3D printing/TTE group, and 27 patients in the conventional group, achieved successful transcatheter closure with a single device. The prevalence of residual shunts was lower in the first group immediately and 6 months post-op, and there were no complications in either group during the procedure or the two follow-ups.

“Gender, age [18.8 ± 15.9 (3–51) years in the 3D printing and TTE group; 14.0 ± 11.6 (3–50) years in the conventional group], mean maximum distance between defects, prevalence of 3 atrial defects and large defect distance (defined as distance ≥7 mm), and occluder size used were similarly distributed between groups,” the team wrote. “However, the 3D printing and TTE group had lower frequency of occluder replacement (3.8% vs 59.3%, ), prevalence of mild residual shunts (defined as <5 mm) immediately (19.2% vs 44.4%, ) and at 6 months (7.7% vs 29.6%, ) after the procedure, and cost (32960.8 ± 2018.7 CNY vs 41019.9 ± 13758.2 CNY, ).”

They did note that the occluder on the 3D printed model was “consistently larger than in the empirical estimation but similar to final clinical selection,” which indicates a higher level of accuracy. Even in patients with a large defect distance, the results of the study suggest that “interventional therapy with a single occluder for multiple ASDs is feasible,” especially as technical difficulties and complex anatomy make successful single device closure tricky to achieve. It’s important to remember that the accuracy of the 3D printed anatomic model is paramount in attaining single device closure in patients with multiple ASDs.

“Occluders’ sizes preestimated by the 3D printed model were similar to the size actually used for patients and larger than the size from conventional empirical estimation. These results indicate that preevaluation using the 3D printed model can avoid unnecessary interventions, the possibility of enlarging ASD by changing occluders and the financial waste of replacing occluders,” they explained.

The researchers ultimately determined that it’s feasible to use a 3D printed model to help achieve successful device closure for patients with multiple ASDs with a defect distance of ≥7 mm. The model can also help screen patients who may not be well-suited for the closure route, and should instead seek direct surgical repair.

“The combination of the 3D printing technology and ultrasound-guided interventional procedure provides a new approach for individualized therapeutic strategy of structural heart disease and in particular a reliable therapeutic method for multiple ASDs, especially for challenging cases with large defect distance,” they concluded.

Discuss this research and other 3D printing topics at 3DPrintBoard.com or share your thoughts below.

The post Researchers Evaluate Feasibility of Closing Multiple Atrial Septal Defects Guided by 3D Printed Model appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

The Maker Movement Unmade? Part 4: Attack of the Clones

Read parts one, two and three of this series. 

Determining a definitive cause of the economic misfortunes of some companies in the open source hardware and maker spaces might prove difficult. However, there was one factor that did seem to clearly impact the desktop 3D printing industry was a flood of low-cost 3D printers from overseas, particularly China.

Starting around 2011 or 2012, clones of open source 3D printers, specifically the MakerBot Replicator, began to appear in the U.S. market. In some cases, the machines were of lesser quality than the originals and, in others, they performed on par or better. In most cases, they were less expensive. Among the earliest copycat brands were Wanhao and FlashForge, which sold the Duplicator and Creator replicas respectively.

At first, it may have seemed as though these Chinese companies were only in the 3D printing business to turnaround a quick profit by taking advantage of open source designs. In part, such skepticism likely stemmed from the different attitudes towards intellectual property, which has resulted in the so-called “pirating” of Western-designed (but often Asian-manufactured) technology.

On the left, the MakerBot Replicator 2. On the right, the Wanhao Duplicator 4.

However, over time, we learned that some of these brands were following in the same maker spirit as their Western counterparts. As Vice General Manager Frank Hua writes on the Wanhao About Us page, “Several Roommates used all [of] their pocket money and bought one Thing-O-Matic from Makerbot. This precious awesome machine brought these college students great enthusiasm [for 3D printing] and help[ed] these budd[ies pursue] their dream. On 1st Oct, WANHAO [replicated] the Thing-O-Matic and named it DUPLICATOR ONE. This 1st Generation Made In China 3D printer has combined most of the advantage[s] of RepRap and Makerbot, and upgrade[d] the extruder to [a non-block] one.”

While the open source aspect of a variety of Chinese models has sometimes been called into question, a number of companies continued to innovate and improve on their foundational copycats. Today, Wanhao has a broad range of 3D printers, including SLA, DLP and FFF. FlashForge products were so well-received that the German engineering multinational Bosch began selling its own version of the FlashForge Creator Pro under its Dremel power tool brand.

As of 2017, China had the most makerspaces in the world, thanks to the government’s Made in China 2025 initiative. The program, launched in 2015, aims to shift the country’s focus from manufacturing low-cost goods for the rest of the world to designing and making high tech products and services for the domestic population. In some cases, this has led to thriving labs of innovation, while in others, the result has been the creation of empty lounges without fabrication equipment.

Xue Yujie at Sixth Tone argues that the stagnation of the maker movement in China is in part due to government pressure for makerspaces to spin out startups and patents. Adafruit points out that similar outcomes can occur with venture capital firms in other parts of the world when too much money is poured into a project and the focus is on forced growth, rather than organic growth.

Electronics at a Shenzhen market. Image courtesy of The Long + Short.

An article in The Long + Short, however, frames the concept of “making”, in the makerspace sense of the word, somewhat differently. The authors describe in the detail the Chinese city of Shenzen, the once-quiet fishing town that now manufactures about 90 percent of the world’s electronics, including pirated goods. Whereas the word “shanzhai” once referred to counterfeit goods, the authors suggest that it now represents the pinnacle of open manufacturing.

With open air markets selling everything from scraps (“reels of resistors, bags of PCB boards, iPhone volume buttons by the bucket”) to complete products (“3D printers, drones of all sizes, and fake Apple watches with bonus features like front-facing cameras”), the city is constantly “making”. These goods are not just mass manufactured products for the rest of the world, but even “niche, often culturally specific products no big companies bother with.”

The authors highlight the hoverboard as a paragon of shanzhai innovation in that the self-balancing scooter had no single inventor but was created in a collaborative fashion online and through informal manufacturing networks. Once it became popular, over 1,000 factories began to produce the item without concern for branding.

It was this same open ecosystem that may have contributed to the transformation of the desktop 3D printing industry and maker movement. The Long + Short authors also highlight how quickly product development can occur in Shenzhen, where the components needed for a prototype can be found “at the market around the corner, or more likely ordered to your exact specification as soon as you want it… Build your prototype, head to the assembly line to push out 10,000 of them, put them out to market, see what sells.”

3D printing, in general, is pitched as a tool for speeding up the design cycle, but, in the case of a massive contract manufacturer, owning the means of production itself speeds up the entire manufacturing process that much more. Located just off the coast of the Chinese mainland on the island of Taiwan, New Kinpo Group oversees the making of such name brand goods as HP printers and Dyson Vacuums, as well as its own line of products.

da Vinci 2.1 AIO 1 with built-in 3D scanner.

At CES 2014, the manufacturing giant unveiled its first desktop 3D printer, the da Vinci 1.0, under its new 3D printing brand, XYZprinting. With a price of $499, the system was among the least expensive on the market at the time. As the stocks of major 3D printing companies like 3D Systems and Stratasys started to crash, XYZ’s printer line began to blow up, including low-cost SLA and DLP systems, as well as FFF 3D printers with price tags as low as $169.

Just as in the case of the Shenzhen electronics manufacturers, New Kinpo Group is able to move quickly from design iteration to manufacturing. The variety of systems sold by XYZprinting to this day is extremely broad, including many variations on the same model (with wi-fi or without; with LCD screen or without; with all-in-one 3D scanner, laser engraver and full-color inkjet printhead or without). The company is consistently able to showcase new technologies, such as food 3D printers, with which it can test market readiness and then decide whether or not it will release them.

Based on one report, at one point, XYZprinting boasted more printer sales than any other company in the market, likely overwhelming the competition. As a result, other manufacturers may not have been able to keep up. Brook Drumm, for instance, remarked in a post-Printrbot interview that “cheap Chinese-made printers, AND Amazon.com selling them, AND Americans choosing to buy them – it all contributed significantly to Printrbot’s demise.”

After the 2014 stock bubble, the 3D printing industry began to experience more growth in the industrial segment with the consumer sector seemingly entering a decline. With that dynamic in the works, XYZ has since decided to shift focus on industrial and professional printers, as well. All of this played into this author’s perception that perhaps the maker movement had started to die off.

However, based on communications with a number of prominent members of said movement, ranging from RepRap luminaries like Richard “RichRap” Horne to former Silicon Valley execs like Carl Bass, it hasn’t died—just transformed.

Read parts one, two and three of this series. 

The post The Maker Movement Unmade? Part 4: Attack of the Clones appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

4D Printing in China: Shape Memory Polymers and Continuous Carbon Fiber

Researchers have been looking further into the benefits of shape memory polymers (SMPs) with the addition of raw materials in the form of continuous carbon fiber (CCF). Authors Xinxin Shen, Baoxian Jia, Hanxing Zhao, Xing Yang, and Zhengxian Liu have studied mechanical properties in composite samples, along with performance—outlining details in the recently published ‘Study on 3D printing process of continuous carbon fiber reinforced shape memory polymer composites.’

SMPs are a ‘hotspot in academic research’ today as scientists embrace a growing fascination with materials that can deform and return to their natural state as required by users. Refining SMPs continues also, especially with materials like carbon fibers for overcoming challenges regarding strength and stiffness. While continuous fibers have been shown to be more effective than short fibers, the authors point out that forming processes are complex, and better ways are needed for creating continuous carbon fiber-reinforced composites. Here, they turn to FDM 3D printing as a solution:

“The composite 3D printer was mainly composed of motion platform, printing nozzle, fiber feeding mechanism and control system,” stated the researchers. “Compared with conventional printers, the nozzle of this printer can feed resin and fiber from two channels simultaneously and extrude them from the same nozzle.”

Printing principle of continuous carbon fiber reinforced SMP composites.

“In addition, the fiber feeding mechanism was designed to continuously feed the fiber at a suitable speed by adjusting the rotating speed of the stepping motor to avoid breakage of the fiber during printing.”

Four ply angles of carbon fibers, (a) 0° (b) 90° (c) 0° /90° (d) ±45°.

In using orthogonal experimental design, the authors studied influences such as:

  • Printing temperature
  • Printing speed
  • Scanning pitch
  • Ply angle

Partial printed specimens with different process parameters.

In examining issues with mechanical properties further, the researchers found that the ply angle of carbon factors was a key factor. As they varied ply angles, changes in tensile strength and modulus of the specimens resulted, showing tension along the fibers at 0 degrees, but at 90 degrees it was perpendicular, opening the potential for problems with adhesion.

The study also showed that mechanical properties were more suitable at about 200℃, with excessive printing speed affecting ‘impregnation’ of fibers and resin. The authors also noted little effect on SMPs due to changes in fiber content.

SEM of fracture cross section of specimens under different temperatures

“The rapid manufacture of shape memory carbon fiber composites has potential use in the field of aerospace,” concluded the researchers.

While researchers, engineers, designers, and users around the world still may have yet to scratch the surface of the potential of 3D printing, many are delving further into the next level with materials that are able to morph to their environments, from soft actuators to 4D printing with wood composites, to exceptional new metamaterials.

Find out more about carbon fiber and SMPs here. 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.

Shape memory performance test with different fiber contents.

[Source / Image: ‘Study on 3D printing process of continuous carbon fiber reinforced shape memory polymer composites’]

 

The post 4D Printing in China: Shape Memory Polymers and Continuous Carbon Fiber appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Interview with Edi Weigh of 3D Printing Service FacFox

In terms of 3D printing, China is still a big unknown. Yes, we’re all familiar with printers from firms such as Flashforge that can be found all over the world. Beyond those global players however, China is a bit of a mystery for us. As you may have noticed, we’re doing many articles on women in 3D printing, 3D printing in Africa, 3D printing resellers, and 3D printing in South America. We hope to reach underexposed 3D printing areas and stories in order to give you a better picture of the entire industry, as it is not as the media imagines it to be. Now, we’ll also take more of a closer look at what is going on in China.

Beyond desktop printers, there is a growing and vibrant Chinese 3D printing industry emerging and they may yet challenge established European and American companies. One such emerging firm is FacFox, a 3D printing service that started with humble desktop 3D printers and in a few years grew to a large and diversified service working with clients all over the globe. We talked to Edi Weigh at FacFox to find out more.

Weigh sees, “FacFox as a one-stop manufacturing platform to realize creation, we make the ideal into real products.”

“It all started with a tiny spark of inspiration when we were college students, after hearing about the 3D printer’s capability and it’s potential in creative and manufacturing industry, so we came across the idea to start a workshop that provides customized 3D printing service. We bought our first Prusa Mendel at 2013, then MakerBot 2X and Rostock Delta Printer in 2015.”

FacFox’s workshop in 2014

Beginning with entry level systems was always going to be a challenge. Given the state of systems in 2014, this would have been almost impossible unless one was armed with extreme perseverance. Interestingly, India’s largest service bureau Objectify also started with desktop machines. In Europe and the US services commonly start with much larger entry-level industrial systems. Whereas Objectify stuck to a centralized service however, FacFox took a much more distributed path.

“a while after the establishment of our workshop, a serious issue started to bother us. With only a few FDM 3D printers we were not able to meet the diversified requirements of clients’ projects. That was when we realized that we needed to embrace the power of a collaborative network. So we created a first primitive website to display the 3D printers connected to us.”

Weigh says, “yes, we got inspiration from 3Dhubs and we really appreciate it.” Rather than focus on consumer 3D printers however, FacFox became a network connecting industrial 3D printing companies in China.

“By 2015, we had gathered over 200 printing companies in China, and started to provide informational services to connect those companies with customers. It didn’t work as expected since there is no added value by only sharing information with 3D printing services, what’s more, the biggest issue remained unsolved: versatility.”

The company clearly had to experiment more with their business model and offering but importantly it was acquiring knowledge.

“If you ask me, what was very beneficial to us in this period, I’d say we learned the limits of 3D printing(especially FDM 3D Printing). Clients want a turnkey solution to realize their creations, the method to achieve this goal is not their top concern. So we started to collect information of both additive and substractive manufacturing methods, and opened our own consulting business to provide a one-stop production plan.”

Pivoting from an in house desktop service towards a 3DHubs for industrial and then yet again towards a one-stop design and fulfillment service may seem dizzying but it shows a company that evolves to meet the market.

 “In 2016, we were funded by venture capital and grew rapidly by partnering with the largest 3D printer manufacturers and service providers, we started to step outside our country and target the global market. Now we have full-stack solution for different industries. This is what keeps us growing.”

Right now FacFox offers 3D printing in metal and polymers, CNC, urethane casting, blow molding, injection molding, sheet fabrication, die casting and other processes through one portal. In other places, 3D printing services may be more focused on polymers for example or perhaps even on one technology. Weigh believes that having lots of options helps customers to do what they need. The firm has EOS M280, EOS M400, ConceptLaser M2 and Farsoon and Zrapid metal printers, and offers SST 316L, Aluminium, Bronze, Titanium, Co-Cr, IN625 and IN718.

“It is crucial that 3D printing and CNC machining are both provided, both methods have their own Pros and Cons, 3D printing is fast and cost-efficient for objects with small size and complex geometry, however CNC machining is more accurate and stable in dimensional accuracy, which also costs a lot less in large objects and bulk production. We need to provide an optimal solution to produce a client’s project irrespective of the technology.”

The company considers its key to success is “to think thoroughly about the value you can offer to the client, don’t recommend 3D printing just because it’s lucrative, only by selecting the method with the best quality versus cost can you gain trust and satisfaction from your clients.”

The company really believes in its turnkey solutions approach and thinks that this will save clients time, money and worry.

Weigh sees FacFox’s “core value is to minimize the expense and maximize the quality and efficiency, which is exactly what we pursue. If you are seeking to realize your creation in the best method, then we are the right one you are looking for.”

The post Interview with Edi Weigh of 3D Printing Service FacFox appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

University of Nottingham: 3D Printed PG/PLA Composites for Repairing Fractures

In ‘Mechanical properties and in vitro degradation behavior of additively manufactured phosphate glass particles/fibers reinforced polyactide,’ authors Lizhe He, Jiahui Zhong, Chenkai Zhu, and Xiaoling Liu explore a new level of material for 3D printing with phosphate glass/polylactide (PG/PLA) composites for use in medical applications such as fabrication of customized bone fixation plates for repairing fractures.

While bone regeneration is an area of great interest in 3D printing and additive manufacturing, so is the more common element of healing breaks, as researchers continue to look for better ways to improve the process—often accompanied by a range of bone fixation plates, screws, pins, and rods. Materials are key, along with integrity in design. Implants must be biocompatible, but the process is seamless when they are biodegradable too, thus eliminating the need for surgery.

The materials were tested for suitable mechanical properties as well as in vitro degradation behavior after creating models designed with PTC Creo Parametric, which were then imported into Simplify3D and the PG/PLA composites were 3D printed on an Ultimaker 2+. With the ability to fabricate complex geometries, the researchers could also control the level of porosity for bioprinting and tissue engineering purposes.

“Comparisons were made with PLA, and PLA reinforced with different loadings of PG particles (PGPs) as well as composites with reinforcements of different geometries [PGPs or milled phosphate glass fibers (PGFs)].”

The aim was to evaluate the AM composites as fracture fixation plates. A three-point bending test was performed, along with in vitro degradation for examining the strength and hydroscopy of the composites. There was a pH value check, along with dynamic mechanical analysis, and fiber length and laser particle size analysis. Both microscopy and statistical analysis were performed also.

Initial flexural properties of the FDM fabricated PLA, PGP/PLA, and PGF/PLA composites. Error bars represent standard deviation. Significance was marked with: * (p < 0.05, n = 5), ** (p < 0.01, n = 5) in black (strength) and red (modulus).

In continuing to compare with PLA specimens, the authors noted the following:

  • Improved flexural modulus
  • Reduced flexural strength
  • Reduced strain at break
  • Intensified effects with increased PGP loading

Typical stress–strain curves of the three‐point bending test of the FDM fabricated PLA, PGP/PLA, and PGF/PLA composites.

“Embrittlement and strength reduction are associated with of stress concentration and low interfacial strength. It is likely here that the stress concentration effect was augmented by the incorporation of particulate with sharp corners. With increased filler loading, stress concentration sites also increased and led to more pronounced strength reduction and the same effect on strain at failure,” noted the authors.

Here, the average fiber length was 54 μm, and median and mode of fiber length were even lower. In comparison to authentic cortical bones, the PGF 10 composite was noted by the researchers to be ‘a close approximation,’ although flexural modulus was found to be considerably lower.

“Stiffness matching is recognized as the ‘gold standard’ for bone fixation implants, as fixation implants with such mechanical properties are strong and stiff enough for the load‐bearing activities without leading to ‘stress shielding.’ As such, it is probably necessary to consider the use of higher/longer fiber loading for this type of application,” stated the researchers.

Continuous PGF/PLA composites are more ‘suitable,’ according to the authors, in regard to load-bearing fixation—a feature connected with continuous fibers leading to stiffness. The flexural modulus of these materials, however, was reduced by ~80% after 28 days of degradation. The PGF 10 composites lost ~30% of initial flexural modulus after a degradation period of 56 days. The rapid flexural modulus could have been a result of the fiber ends being exposed in degradation media.

“Based on the consideration of both the initial mechanical properties and the facility to produce composites with desired geometries straightforwardly, the additive manufacturing of PG/PLA composites exhibits good potential in the making of patient‐specific fixation implants for bone that has low demand for load‐bearing, for example, zygoma, ankle, and maxilla,” concluded the researchers.

“These bones have been previously reported to be successfully restored using PLA‐based biodegradable fixation devices. Compared to PLA alone, it was demonstrated that the incorporation of PGF enhanced the flexural modulus of implants. It is also anticipated that the degradation of PGF releases magnesium, calcium, and phosphate to upregulate bone regrowth. Moreover, the FDM process allows fixation implants with customized geometries to be built directly and may remove the need for contouring of implants for anatomic fit during the operation.”

A serious interest in 3D printing today translates into a serious interest in materials—and most likely composites too, as they are able to add significant strength and improved properties to prototypes and parts, including that of polymers, bioprinting applications, and metals like titanium. 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.

SEM images of polished/pristine fractured surfaces of virgin PLA (a,b); PGP 10 (c,d); PGP 20 (e,f); and PGF 10 (g,h) composites

SEM images of pristine fractured surfaces of PLA (a,b); PGP 10 (c,d); PGP 20 (e,f); and PGF 10 (g,h) degraded at 37 °C in PBS for 28/56 days.

SEM images showing the fusion of PGPs (a) and PGFs (b) into excrescences, captured on Day 56.

[Source / Images: ‘Mechanical properties and in vitro degradation behavior of additively manufactured phosphate glass particles/fibers reinforced polyactide‘]

The post University of Nottingham: 3D Printed PG/PLA Composites for Repairing Fractures appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

China: Researchers Improve Rib Fracture Surgeries with 3D Printing

In ‘Analysis of the advantages of 3D printing in the surgical treatment of multiple rib fractures: 5 cases report,’ Chinese researchers from Shijiazhuang Third Hospital explore better ways to treat rib fractures, one of the most common types of breaks; in fact, as the authors point out, they make up nearly 80 percent of chest injuries. For this study, they examined cases of five patients with multiple rib fractures and created 3D models of the ribs, plus pre-shaped titanium alloy rib locking plates.

Research in past years has shown that ‘surgical intervention’ often results in better outcomes for patients with multiple rib fractures. There are, however, complex considerations in working with fracture sites that are more unique—presenting challenges for surgeons in deciding where to perform incisions. This is where the benefits of 3D printed models enter the picture, allowing for better planning for surgeries.

The study was ongoing from January 2017 to August 2018, examining all five patients, each of which had CT scans to confirm fractures. In each case, 3D printed models were made, and the rib locking plates were 3D printed—specifically to each patient:

Patient one – a 61-year-old male. The 3D printed model assisted in the creation of a two-rib titanium alloy frame locking plate ‘placed on the 3rd rib’s surface, and well fitted with the non-fractured end of the 3rd rib front and rear.’

No.1 patient (a) Preoperative scanning revealed long segment comminuted fractures in 3 and 4 ribs. b Preoperative 3 and 4 rib models were prepared by 3D printing technology based on CT thin slice scanning. c, d Reduction fracture morphology; the 3D printing model was spliced and the titanium alloy rib locking plate was shaped according to the mode. e Postoperative review, the shape of the internal fixator was intact, and the shape of the contralateral rib was perfectly symmetrical compared with preoperative image A

Patient two – a 57-year-old male with multiple fractures of the left ribs. Surgeons decided to attach the inner end of the locking plate to the sternum the outer end to the rib bone.

No.2 patient (a) According to the 3D model made by CT, 4 and 5 costal cartilage fractures and 6 costal anterior costal arch fracture can be seen. b The 3D model of the fracture end of the rib was adjusted by using 3D software model. c The 3D printed 4–6 rib model shows a large gap between the locking plate and the shape of the rib. d After giving the shape, the locking plate and the rib paste are in good condition. e, f Postoperative review, the shape of the internal fixator was intact, and the shape of the contralateral rib recovered well compared with the preoperative image

Patient three – a 64-year-old female. Surgeons were striving for minimally invasive surgery but were also required to protect breast tissue sufficiently. Ultimately, they affixed the locking plate’s medial side to her sternum body, with the sternum and armpit treated via ‘tunneling open reduction and internal fixation.’

Patients four/five – two male patients both had multiple fractures due to a car accident, with similar surgeries, performed ‘tunneling open reduction and internal fixation.’ A CT scan was used to create 3D models so that the broken ends of their ribs could be ‘adjusted and restored’ accordingly.

No.3 patient (a) Preoperative scanning revealed 2–11 left rib fractures where 2–6 ribs contained the costal cartilage multiple fractures involving the costal arch. b Preoperative 3–5 rib models were prepared by 3D printing technology based on CT thin slice scanning. c During the surgery, corresponding pre-shaping locking plates were placed in each rib

Overall, the study was a success, with no fatalities. Time in the operating room was around three hours at the most for each patient, with only one individual experiencing complications, resulting in an ICU stay for one day, due to respiratory issues.

“Postoperative chest radiographs of each patient showed that the internal fixation had good and natural shape,” stated the researchers. “There was good shape to the thoracic contour and [it] was basically symmetrical with the contralateral side.

“In conclusion, for the 5 cases of multiple rib fractures reported in this study, the preoperative application of 3D printing technology can fully reduce the shaping time of intraoperative internal fixator, the difficulty of operation and the injury of patients.

“Therefore, for some specific types of rib fractures, the preoperative application of 3D printing technology has potential significance in achieving precise and individualized treatment, but this method still needs more clinical experience to provide better services for patients.”

3D printing has offered huge advantages to surgeons, especially with models that can be used before and during surgery, allowing for better patient education, medical training for students and surgeons who may be attempting new procedures, and overall improved patient care.

For fractures of the costal arch, a re-shaped locking plate is required. Adjust the (a) front and back radians of the rib lock, (b) upper and lower radians and (c) the rotation angle of the locking plate of the long axis of the ribs according to the 3D printing model. d the back end of the upper metal bone plate can be seen with abscission screw, the second metal bone plate is not ideal in shape, and the back end and the ribs are not well covered, and the embracing fixator is used as an accessory to prevent abscission

[Source / Images: ‘Analysis of the advantages of 3D printing in the surgical treatment of multiple rib fractures: 5 cases report’]