The quality control of 3D printed structures is significant for the reliability of additively manufactured objects. A novel remote sensing technique for characterizing 3D printed structures was developed by non-destructive ultrasonic imaging of a commonly used thermoplastic object such as acrylonitrile butadiene syrene (ABS). The quality of the additively manufactured ABS slab printed by fused deposition modeling (FDM) technique was evaluated by imaging effective density technique. The infill density of the FDM printed structures were modified by varying the motor speed of the printing extruder. An ultrasonic raster scan of the 3D printed structure using the novel effective density imaging technique distinguished the contrast in density with a very high resolution in the density variation. In addition to the lateral scanning, the density characterization was also effective when applied axially and can probe deep inside the additively manufactured object. The experimentally measured density variation agrees well with the theoretically calculated density values as a function of flow rate. The combined lateral and axial capabilities of the imaging technique make it a promising diagnostic tool for an in situ inspection method of optimizing FDM printing and quality control of 3D printed objects.

Ultrasound is a continually developing technology that is broadly used for fast, non-destructive mechanical property detection of hard and soft materials in applications ranging from manufacturing to biomedical. In this study, a novel monostatic longitudinal ultrasonic pulsing elastography imaging method is introduced. The existing elastography methods require an acoustic radiational or dynamic compressive externally applied force to determine the effective bulk modulus or density. This new, passive M-mode imaging technique does not require an external stress and can be effectively used for both soft and hard materials. Strain map imaging and shear wave elastography are two current categories of M-mode imaging that show both relative and absolute elasticity information. The new technique is applied to hard materials and soft material tissue phantoms for demonstrating effective bulk modulus and effective density mapping. When compared with standard techniques, the effective parameters fall within 10% of standard characterization methods for both hard and soft materials. As neither the standard A-mode imaging technique nor the presented technique require an external applied force, the techniques are applied to composite heterostructures and the findings presented for comparison. The presented passive M-mode technique is found to have enhanced resolution over standard A-mode modalities.

The advent of 3D digital printers has led to the evolution of realistic anatomical organ shaped structures that are being currently used as experimental models for rehearsing and preparing complex surgical procedures by clinicians. However, the actual material properties are still far from being ideal, which necessitates the need to develop new materials and processing techniques for the next generation of 3D printers optimized for clinical applications. Recently, the voxelated soft matter technique has been introduced to provide a much broader range of materials and a profile much more like the actual organ that can be designed and fabricated voxel by voxel with high precision. For the practical applications of 3D voxelated materials, it is crucial to develop the novel high precision material manufacturing and characterization technique to control the mechanical properties that can be difficult using the conventional methods due to the complexity and the size of the combination of materials. Here we propose the non-destructive ultrasound effective density and bulk modulus imaging to evaluate 3D voxelated materials printed by J750 Digital Anatomy 3D Printer of Stratasys. Our method provides the design map of voxelated materials and substantially broadens the applications of 3D digital printing in the clinical research area.

In this study, a novel ultrasonic non-destructive and non-invasive elastography method was introduced and demonstrated to evaluate the mechanical properties of fused deposition modeling 3D printed objects using two-dimensional dynamical elasticity mapping. Based on the recently investigated dynamic bulk modulus and effective density imaging technique, an angle-dependent dynamic shear modulus measurement was performed to extract the dynamic Young’s modulus distribution of the FDM structures. The elastographic image analysis demonstrated the presence of anisotropic dynamic shear modulus and dynamic Young’s modulus existing in the fused deposition modeling 3D printed objects. The non-destructive method also differentiated samples with high contrast property zones from that of low contrast property regions. The angle-dependent elasticity contrast behavior from the ultrasonic method was compared with conventional and static tensile tests characterization. A good correlation between the nondestructive technique and the tensile test measurements was observed.