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The main purpose of this study is to develop a systematic method that can minimize joint clearance for non‐assembly mechanism fabrication using a layer‐based fabrication technology.

Joint clearance is one of the key factors affecting a mechanism's performance. Hertz theory is adopted to analyze the joint clearance‐penetration displacement relationship and the impact force‐displacement relationship. This analysis has indicated the importance of reducing joint clearance. To reduce joint clearance in layer‐based fabrication, a drum‐shaped roller is proposed for pin joint design in non‐assembly mechanism fabrication. Compared to cylindrical pin joint design, a drum‐shaped roller joint results in less impact force in mechanism operation. Furthermore, the joint clearance can also be drastically reduced.

Large joint clearance could introduce instability into the dynamic behaviour of a mechanism. By applying a drum‐shaped roller, the instability could apparently be alleviated. This has been demonstrated by both simulation and fabrication of a number of mechanisms with and without drum‐shaped pin joints.

Since the proposed joint design can reduce the joint clearance in rapid fabrication of non‐assembly mechanisms, it is possible to expand layer‐based rapid fabrication techniques for more mechanism design applications.

Layer‐based fabrication technologies have two distinct advantages: building parts without geometry restriction; and building sub‐systems (static or mobile) without the need for assembly. Only very few previous studies have investigated the applications that can benefit from the second advantage due to the limited accuracy of layer‐based technologies in making joints of a mechanism. Through the proposed drum‐shaped roller pin joint design together with the proposed joint design guidelines, joint clearance can be reduced significantly. Thus, sub‐systems or mechanisms built using layer‐based technologies could have accuracy close to the design specification. This will expand the application of layer‐based technologies to more mechanism or mobile mechanical system studies.

The purpose of this study is to highlight the direct fabrication of rapid tooling (RT) with desired mechanical, tribological and thermal properties using fused deposition modelling (FDM) process. Further, the review paper demonstrated development procedure of alternative feedstock filament of low-cost composite material for FDM to extend the range of RT applications.

The alternative materials for FDM and their processing requirements for fabrication in filament form as reported by various researchers have been summarized. The literature demonstrates the role of various post-processing techniques on surface finish of FDM prints. Further, low-cost materials for feedstock filament have been investigated experimentally to check their adaptability/suitability for commercial FDM setup. The approach was to realize the requirements of FDM (melt flow rate, flexibility, stiffness, glass transition temperature and mechanical strength), necessary for the successful run of an alternative filament. The effect of constituents (additives, plasticizers, surfactants and fillers) in polymeric matrix on mechanical, tribological and thermal properties has been investigated.

It is possible to develop composite material feedstock as filament for commercial FDM setup without changing its hardware and software. Surface finish of the parts can further be improved by applying various post-processing techniques. Most of the composite parts have high mechanical strength, hardness, thermal stability, wear resistant and better bond formation than standard material parts.

Future research may be focused on improving the surface quality of parts fabricated with composite feedstock, solving issues related to the uniform distribution of filled materials during the fabrication of feedstock filament which in turns further increases mechanical strength, high dimensional stability of composite filament and transferring the technology from laboratory scale to various industrial applications.

Potential applications of direct fabrication with RT includes rapid manufacturing (RM) of metal-filled parts and ceramic-filled parts (which have complex shape and cannot be rapidly made by any other manufacturing techniques) in the field of biomedical and dentistry.

This new manufacturing methodology is based on the proper selection and processing of various materials and additives to form high-performance, low-cost composite material feedstock filament (which fulfil the necessary requirements of FDM process). Finally, newly developed feedstock filament material has both quantitative and qualitative advantage in RT and RM applications as compared to standard material filament.

The key principle of the jet deposition rapid prototyping (RP) system is to deliver material through a jet and deposit the liquefied material onto a platform to build a physical model. Model Maker (MM) RP system is one of the jet deposition processes with the smallest slice thickness and better model accuracy. In order to maintain thinner layer thickness and model accuracy, a cutter is employed to plane off the deposited surface. The fabrication speed for MM models is extremely low because of the employment of the tiny jet and the cutting operation. The model interior filling does not affect the model accuracy very much but it does significantly affect the fabrication speed. Hence, a new flexible layer fabrication method is proposed in this paper to separate the fabrication processes of the profile and the interior, respectively, in order to maintain model accuracy and thinner slice thickness, and to accelerate the fabrication speed.

This paper aims to investigate the applicability of 3D-printed molds to be used as a substitute for photolithography in the formation of polymer-based stamps. It proposes leveraging 3D printing as a rapid prototyping tool to be applied to microfluidic fabrication.

Different designs are created using computer-aided design (CAD) software and printed via Makerbot 3D printer. The molds serve as negative reliefs for a PDMS stamp. The stamp is used to apply paraffin wax to chromatography paper, creating hydrophobic barriers and hydrophilic channels. The minimum functional channel widths and barrier widths are determined for the method.

The method is demonstrated to be effective for bypassing the more cost-prohibitive photolithography approach for rapid paper microdevice fabrication. This approach produces functional channels that can be used for on-chip analytical assays. The minimum functional barrier widths and minimum functional channel widths are in good agreement with other published methods for paper-based microchannel fabrication.

The approach cannot generate the high-resolution structures possible with photolithography. Therefore, if higher resolutions are needed for a particular application, this approach is not the best.

The simplicity of the approach introduces an affordable method to create disposable devices that can be used at the point of testing.

The paper satisfies a need for inexpensive, rapid prototyping of paper-based devices. The method is simple and can be used as a tool for introducing labs to microfluidics research.

Fabrication of customized products in low volume through conventional manufacturing incurs a high cost, longer processing time and huge material waste. Hence, the concept of additive manufacturing (AM) comes into existence and fused deposition modelling (FDM), is at the forefront of researches related to polymer-based additive manufacturing. The purpose of this paper is to summarize the research works carried on the applications of FDM.

In the present paper, an extensive review has been performed related to major application areas (such as a sensor, shielding, scaffolding, drug delivery devices, microfluidic devices, rapid tooling, four-dimensional printing, automotive and aerospace, prosthetics and orthosis, fashion and architecture) where FDM has been tested. Finally, a roadmap for future research work in the FDM application has been discussed. As an example for future research scope, a case study on the usage of FDM printed ABS-carbon black composite for solvent sensing is demonstrated.

The printability of composite filament through FDM enhanced its application range. Sensors developed using FDM incurs a low cost and produces a result comparable to those conventional techniques. EMI shielding manufactured by FDM is light and non-oxidative. Biodegradable and biocompatible scaffolds of complex shapes are possible to manufacture by FDM. Further, FDM enables the fabrication of on-demand and customized prosthetics and orthosis. Tooling time and cost involved in the manufacturing of low volume customized products are reduced by FDM based rapid tooling technique. Results of the solvent sensing case study indicate that three-dimensional printed conductive polymer composites can sense different solvents. The sensors with a lower thickness (0.6 mm) exhibit better sensitivity.

This paper outlines the capabilities of FDM and provides information to the user about the different applications possible with FDM.

To present a custom design and fabrication method for a novel hemi‐knee joint substitute composed of titanium alloy and porous bioceramics based on rapid prototyping (RP) and rapid tooling (RT) techniques.

The three‐dimensional (3D) freeform model of a femur bone was reconstructed based on computerized tomography images via reverse engineering and the 3D reconstruction accuracy was evaluated. The negative image of artificial bone was designed with interconnected microstructures (250‐300 μm). The epoxy resin mould of a hemi‐knee joint and the negative pattern of an artificial bone were fabricated on Stereolithography apparatus. Based on these moulds, a titanium‐alloy hemi‐knee joint and a porous‐bioceramic artificial bone were created by quick casting and powder sintering (known as RT) techniques, respectively. After assembling, a composite hemi‐knee joint substitute was obtained.

The 3D reconstructed freeform model of the femur bone conformed to the original anatomy within a maximum deviation 0.206 mm. The sintered artificial bone had interconnected micropores (250 μm) and microchannels (300 μm). After implanting in vivo, the composite hemi‐knee joint substitute matched well with the surrounding tissues and bones with sufficient mechanical strength.

Further in‐vivo research is needed to provide the evidence for tissue growth into the ceramic structures and long‐term viability and stability of the implant.

This method enhances the versatility of using RP in the fabrication of tissue‐engineered substitutes, especially when individual matching is considered. Although this paper took a customized hemi‐knee joint substitute as an example, it is capable of fabricating other artificial substitutes with a variety of biomaterials.

The purpose of this paper is to develop a workflow for design and fabrication of customized surgical guides (CSGs) for placement of the bidirectional extraoral distraction instruments (EDIs) in bilateral mandibular distraction osteogenesis (MDO) surgery to treat the bilateral temporomandibular joint ankylosis with zero mouth opening.

The comprehensive workflow consists of six steps: medical imaging; virtual surgical planning (VSP); computer aided design; rapid prototyping (RP); functional testing of CSGs and mock surgery; and clinical application. Fused deposition modeling, an RP process was used to fabricate CSGs in acrylonitrile butadiene styrene material. Finally, mandibular reconstruction with MDO was performed successfully using RP-assisted CSGs.

Design and development of CSGs prior to the actual MDO surgery improves accuracy, reduces operation time and decreases patient morbidity, hence improving the quality of surgery. Manufacturing of CSG is easy using RP to transfer VSP into the actual surgery.

This study describes an RP-assisted CSGs fabrication for exact finding of both; osteotomy site and drilling location to fix EDI’s pins accurately in the mandible; for accurate osteotomy and placement of the bidirectional EDIs in MDO surgery to achieve accurate distraction.

As an application of the computer aided design and computer aided manufacturing (CAD/CAM) technology in prosthetics, computer aided socket design and computer aided socket manufacturing (CASD/CASM) is becoming an active field in the prosthetics research. In this paper, a CASD/CASM method for prosthetic socket fabrication is described in detail. This is different from other fabrication methods in its novel combination of the CAD/CAM technology with fused deposition modeling (FDM) technology. Prosthetic sockets for volunteer amputees have been designed and fabricated in a FDM machine. In order to test the fabrication result, a final product was used to perform a clinical trial and some results are reported. In addition, the deficiency of the long fabrication time is addressed and some feasible solutions are discussed.

This paper aims to provide an overview of applications of medical rapid prototyping (MRP)-assisted customized surgical guides (CSGs) and shows the potential of this technology in complex surgeries. This review paper also reports two case studies from open literature where MRP-assisted CSGs have been successfully used in complex surgeries.

Key publications from the past two decades have been reviewed.

This study concludes that the use of MRP-assisted CSGs improves the accuracy of surgery. Additionally, MRP-assisted CSGs make the surgery much faster, accurate and cheaper than any other technique. The outcome based on literature review and two case studies strongly suggested that MRP-assisted CSGs might become part of a standard protocol in the medical sector to operate the various complex surgeries, in the near future.

Advanced technologies like radiology, image processing, virtual surgical planning (VSP), computer-aided design (CAD) and MRP made it possible to fabricate the CSGs. MRP-assisted CSGs can easily transfer the VSP into the actual surgery.

This paper is beneficial to study the development and applications of MRP-assisted CSGs in complex surgeries.

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.