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This paper aims to present a novel rapid prototyping (RP) fabrication methods and preliminary characterization for chitosan scaffolds.

A desktop rapid prototyping robot dispensing (RPBOD) system has been developed to fabricate scaffolds for tissue engineering (TE) applications. The system is a computer‐controlled four‐axis machine with a multiple‐dispenser head. Neutralization of the acetic acid by the sodium hydroxide results in a precipitate to form a gel‐like chitosan strand. The scaffold properties were characterized by scanning electron microscopy, porosity calculation and compression test. An example of fabrication of a freeform hydrogel scaffold is demonstrated. The required geometric data for the freeform scaffold were obtained from CT‐scan images and the dispensing path control data were converted form its volume model. The applications of the scaffolds are discussed based on its potential for TE.

It is shown that the RPBOD system can be interfaced with imaging techniques and computational modeling to produce scaffolds which can be customized in overall size and shape allowing tissue‐engineered grafts to be tailored to specific applications or even for individual patients.

Important challenges for further research are the incorporation of growth factors, as well as cell seeding into the 3D dispensing plotting materials. Improvements regarding the mechanical properties of the scaffolds are also necessary.

One of the important aspects of TE is the design scaffolds. For customized TE, it is essential to be able to fabricate 3D scaffolds of various geometric shapes, in order to repair tissue defects. RP or solid free‐form fabrication techniques hold great promise for designing 3D customized scaffolds; yet traditional cell‐seeding techniques may not provide enough cell mass for larger constructs. This paper presents a novel attempt to fabricate 3D scaffolds, using hydrogels which in the future can be combined with cells.

This study aims to develop a data fusion method for powder-bed fusion (PBF) process monitoring based on process image information. The data fusion method can help improve process condition identification performance, which can provide guidance for further PBF process monitoring and control system development.

Design of reliable process monitoring systems is an essential approach to solve PBF built quality. A data fusion framework based on support vector machine (SVM), convolutional neural network (CNN) and Dempster-Shafer (D-S) evidence theory are proposed in the study. The process images which include the information of melt pool, plume and spatters were acquired by a high-speed camera. The features were extracted based on an appropriate image processing method. The three feature vectors corresponding to the three objects, respectively, were used as the inputs of SVM classifiers for process condition identification. Moreover, raw images were also used as the input of a CNN classifier for process condition identification. Then, the information fusion of the three SVM classifiers and the CNN classifier by an improved D-S evidence theory was studied.

The results demonstrate that the sensitivity of information sources is different for different condition identification. The feature fusion based on D-S evidence theory can improve the classification performance, with feature fusion and classifier fusion, the accuracy of condition identification is improved more than 20%.

An improved D-S evidence theory is proposed for PBF process data fusion monitoring, which is promising for the development of reliable PBF process monitoring systems.

This study aims to further the understanding of support structures and the likely impacts on maraging steel MS1 parts fabricated by selective laser melting (SLM) at 45°, 60° and 75° building angles.

Two groups of samples, one group with support structures and the other group without support structures, were designed with the same specifications and printed under the same conditions by SLM at 45°, 60° and 75° building angles. Differences in dimensional accuracy, surface roughness, Vickers microhardness, residual stress and microstructure were compared between groups.

The results showed that with support structures, more accurate dimension and slightly higher Vickers microhardness could be obtained. Larger compressive stress dominated and was more uniformly distributed on the supporting surface. Without support structures, the dimension became more precise as the building angle increased and alternating compressive and tensile stress was unevenly distributed on the supporting surface. In addition, the surface roughness of the outer surface decreased with the increase of the built angle, regardless of the support structures. Furthermore, whether the building angle was 45°, 60° or 75°, the observed microstructures revealed that the support structures altered the orientation of the molten pool and the direction of grain growth.

This paper studies the influence of support structures on the workpieces printed at different building angles. Support structures affect the residual stress distribution, heat dissipation rate and microstructure of the parts, and thus affecting the printing quality. Therefore, it is necessary to balance the support strategy and printing quality to better apply or design the support structures in SLM.

Fabricating functionally graded scaffolds to mimic the complex spatial distributions of the composition, micro-structure and functionality of native tissues will be one of the key objectives for future tissue engineering research. This study aims to create a scaffold to mimic functionally-graded tissue using a hybrid process, which incorporated electrospun polycaprolactone (PCL) and electrosprayed hydroxyapatite (HA) in a simple pathway.

The PCL and HA were dispensed simultaneously from different positions to form a layer on a rotational mandrel, and a gradient construct was achieved by adjusting dispensing rates of both materials.

The morphology of scaffolds changed gradually from one layer to another layer with the change of the dispensing conditions of the two materials. The elemental distribution analysis revealed that C/Ca ratio linearly increased with certain dispensing rate ratio of PCL:HA. In addition, the thickness, mechanical properties (i.e. ultimate tensile stress and Young’s modulus), surface roughness and water contact angle of each layer changed accordingly with the variation of dispensing rate of PCL and HA, and the diameter distributions of PCL fibres and HA particles did not vary significantly.

This study showed the hybrid process has the potential to be used in fabrication of scaffold with functionally graded structure for tissue engineering applications, especially for mimicking the nature of the native 3D tendon–bone interface.

This paper aims to present an optimal prototyping technology for the manufacture of occlusal splints.

To carry out this study, a comparative technique was used to analyze models obtained by different prototyping techniques. Subsequently, further tests were carried out with respect to the manufacturing of splints by means of thermoforming in a vacuum. This involved an analysis of the most important variables such as prototype material, geometric accuracy, surface finish and costs.

It was found that there is a group of prototyping technologies that are suitable for the manufacture of the models used in the thermoforming of correction splints, the most appropriate technologies being based on ink jet printing (IJP-Objet), ultraviolet photo polymerization and fused deposition modelling due to the fact that they offer an optimal relationship between the cost and the quality of the model required for thermoforming.

The application of rapid prototyping techniques in medicine makes the production of physical models from three-dimensional medical image processing and their subsequent use in different specialties possible. It also makes preoperative planning processes, the production of prostheses and the preparation of surgical templates possible, thereby offering a higher quality of diagnosis, safer surgery and cost and time savings compared to conventional manufacturing technologies.

This paper suggests that there exists a group of prototyping technologies for the manufacture of splints that offer advantages over existing technologies. The results also suggest that, in many cases, the most expensive technology is not the most appropriate: there are other options that provide an optimal model in terms of the cost and the quality needed for thermoforming.