In idiopathic pulmonary fibrosis (IPF), the fibroblast focus is a key histological feature representing active fibroproliferation. On standard 2D pathologic examination, fibroblast foci are considered small, distinct lesions, although they have been proposed to form a highly interconnected reticulum as the leading edge of a “wave” of fibrosis. Here, we characterized fibroblast focus morphology and interrelationships in 3D using an integrated micro-CT and histological methodology. In 3D, fibroblast foci were morphologically complex structures, with large variations in shape and volume (range, 1.3 × 10 ⁴ to 9.9 × 10 ⁷ μm ³ ). Within each tissue sample numerous multiform foci were present, ranging from a minimum of 0.9 per mm ³ of lung tissue to a maximum of 11.1 per mm ³ of lung tissue. Each focus was an independent structure, and no interconnections were observed. Together, our data indicate that in 3D fibroblast foci form a constellation of heterogeneous structures with large variations in shape and volume, suggesting previously unrecognized plasticity. No evidence of interconnectivity was identified, consistent with the concept that foci represent discrete sites of lung injury and repair.

Advanced manufacturing technologies, led by additive manufacturing, have undergone significant growth in recent years. These technologies enable engineers to design parts with reduced weight while maintaining structural and functional integrity. In particular, metal additive manufacturing parts are increasingly used in application areas such as aerospace, where a failure of a mission-critical part can have dire safety consequences. Therefore, the quality of these components is extremely important. A critical aspect of quality control is dimensional evaluation, where measurements provide quantitative results that are traceable to the standard unit of length, the metre. Dimensional measurements allow designers, manufacturers and users to check product conformity against engineering drawings and enable the same quality standard to be used across the supply chain nationally and internationally. However, there is a lack of development of measurement techniques that provide non-destructive dimensional measurements beyond common non-destructive evaluation focused on defect detection. X-ray computed tomography (XCT) technology has great potential to be used as a non-destructive dimensional evaluation technology. However, technology development is behind the demand and growth for advanced manufactured parts. Both the size and the value of advanced manufactured parts have grown significantly in recent years, leading to new requirements of dimensional measurement technologies. This paper is a cross-disciplinary review of state-of-the-art non-destructive dimensional measuring techniques relevant to advanced manufacturing of metallic parts at larger length scales, especially the use of high energy XCT with source energy of greater than 400 kV to address the need in measuring large advanced manufactured parts. Technologies considered as potential high energy x-ray generators include both conventional x-ray tubes, linear accelerators, and alternative technologies such as inverse Compton scattering sources, synchrotron sources and laser-driven plasma sources. Their technology advances and challenges are elaborated on. The paper also outlines the development of XCT for dimensional metrology and future needs.

Acoustic emission (AE) is a non-destructive technique that is capable of passively monitoring failure of a construct with excellent temporal resolution. Previous investigations using AE to monitor the integrity of a total hip replacement (THR) have used surface mounted sensors; however, the AE signal attenuates as it travels through materials and across interfaces. This study proposes that directly embedded sensors within the femoral stem of the implant will reduce signal attenuation effects and eliminate potential complications and variability associated with fixing the sensor to the sample. Data was collected during in vitro testing of implanted constructs, and information from both embedded and externally mounted AE sensors was compared and corroborated by micro-Computed Tomography (micro-CT) images taken before and after testing. The results of this study indicate that the embedded sensors gave a closer corroboration to observed damage using micro-CT and were less affected by unwanted noise sources. This has significant implications for the use of AE in assessing the state of THR constructs in vitro and it is hypothesised that directly embedded AE sensors may provide the first steps towards an in vivo, cost effective, user friendly, non-destructive system capable of continuously monitoring the condition of the implanted construct.

Micro-focus X-ray computed tomography (CT) can be used to quantitatively evaluate the packing density, pore connectivity and provide the basis for specimen derived simulations of gas permeability of sand mould. This non-destructive experiment or following simulations can be done on any section of any size sand mould just before casting to validate the required properties. This paper aims to describe the challenges of this method and use it to simulate the gas permeability of 3D printed sand moulds for a range of controlling parameters. The permeability simulations are compared against experimental results using traditional measurement techniques. It suggests that a minimum volume of only 700 × 700 × 700 µm³ is required to obtain, a reliable and most representative than the value obtained by the traditional measurement technique, the simulated permeability of a specimen. X-ray tomography images were used to reconstruct 3D models to simulate them for gas permeability of the 3D printed sand mould specimens, and the results were compared with the experimental result of the same. The influence of printing parameters, especially the re-coater speed, on the pore connectivity of the 3D printed sand mould and related permeability has been identified. Characterisation of these sand moulds using X-ray CT and its suitability, compared to the traditional means, are also studied. While density and 3PB strength are a measure of the quality of the moulds, the pore connectivity from the tomographic images precisely relates to the permeability. The main conclusions of the present study are provided below. A minimum required sample size of 700 × 700 × 700 µm³ is required to provide representative permeability results. This was obtained from sand specimens with an average sand grain size of 140 µm, using the tomographic volume images to define a 3D mesh to run permeability calculations. Z-direction permeability is always lower than that in the X-/Y-directions due to the lower values of X-(120/140 µm) and Y-(101.6 µm) resolutions of the furan droplets. The anisotropic permeability of the 3D printed sand mould is mainly due to, the only adjustable, X-directional resolution of the furan droplets; the Y-directional resolution is a fixed distance, 102.6 µm, between the printhead nozzles and the Z-directional one is usually, 280 µm, twice the size of an average sand grain.A non-destructive and most representative permeability value can be obtained, using the computer simulation, on the reconstructed 3D X-ray tomography images obtained on a specific location of a 3D printed sand mould. This saves time and effort on printing a separate specimen for the traditional test which may not be the most representative to the printed mould. The experimental result is compared with the computer simulated results.