This work addresses the topic of extrusion-based additive manufacturing (filament-based material extrusion) of patient-specific biofunctional maxillofacial implants. The technical approach was chosen to overcome the shortcomings of medically established fabrication processes such as a limited availability of materials or long manufacturing times. The goal of the work was a successful fabrication of basic implants for defect reconstruction. The underlying vision is the implants’ clinic-internal and operation-accompanying application. Following a literature search, a material selection was conducted. Digitally prepared three-dimensional (3D) models dealing with two representative mandible bone defects were printed based on the material selection. An ex-vivo model of the implant environment evaluated dimensional and fitting traits of the implants. Glycol-modified PET (PETG) and thermoplastic polyurethane (TPU) were finally selected. These plastics had high cell acceptance, good mechanical properties, and optimal printability. The subsequent fabrication process yielded two different implant strategies: the standard implant made of PETG with a build-up rate of approximately 10 g/h, and the biofunctional performance implant with a TPU shell and a PETG core with a build-up rate of approximately 4 g/h. The standard implant is meant to be intraoperatively applied, as the print time is below three hours even for larger skull defects. Standard implants proved to be well fitting, mechanically stable and cleanly printed. In addition, the hybrid implant showed particularly cell-friendly behavior due to the chemical constitution of the TPU shell and great impact stability because of the crack-absorbing TPU/PETG combination. This biofunctional constellation could be used in specific reconstructive patient cases and is suitable for pre-operative manufacturing based on radiological image scans of the defect. In summary, filament-based material extrusion has been identified as a suitable manufacturing method for personalized implants in the maxillofacial area. A further clinical and mechanical study is recommended.

Combining thermal conductivity with electrical isolation is a very interesting topic for electronic applications in order to transfer the generated heat. Typical approaches combine thermally conductive fillers with a thermoplastic matrix. The aim of this work was to investigate the influence of different fillers and matrices on the thermal conductivity of the polymer matrix composites. In this study, various inorganic fillers, including aluminum oxide (Al₂O₃), zinc oxide (ZnO), and boron nitride (BN) with different shapes and sizes, were used in matrix polymers, such as polyamide 6 (PA6), polypropylene (PP), polycarbonate (PC), thermoplastic polyurethane (TPU), and polysulfone (PSU), to produce thermally conductive polymer matrix composites by compounding and injection molding. Using simple mathematical models (e.g., Agari model, Lewis–Nielson model), a first attempt was made to predict thermal conductivity from constituent properties. The materials were characterized by tensile testing, density measurement, and thermal conductivity measurement. Contact angle measurements and the calculated surface energy can be used to evaluate the wetting behavior, which correlates directly with the elastic modulus. Based on the aforementioned evaluations, we found that besides the volume fraction, the particle shape in combination with the intrinsic thermal conductivity of the filler has the greatest influence on the thermal conductivity of the composite.

Considering the major role played by sandwich structures in many fields where high stiffness-to-weight ratio is required, the selection of a suitable core material is of paramount importance. In order to face the environmental problems related to waste disposal, the selection of an eco-friendly core material is now included in the design criteria of sandwich structures. Agglomerated cork is recognized as a good solution that combines satisfactory mechanical performances and eco-sustainability. Many research studies individually addressed cork’s morphological, thermal, and mechanical features without providing a comprehensive overview of the relationships that exist between them. In this work, the investigation of the peculiar cork morphology allowed learning more about its good insulation capacity and its impressive recovery capability. The use of dynamic mechanical analysis (DMA) and thermogravimetric analysis (TGA) clarified the influence of temperature on both flexural and compressive performances. The effect of testing parameters such as temperature and speed on agglomerated cork properties was validated through statistical analysis. Moreover, to highlight agglomerated cork advantages and drawbacks, the work provides also a comparison with more traditional polyvinylchloride (PVC) foams commonly used in industrial applications.

In this work, the relation of injection molding parameters to the mechanical properties of various polypropylene grades is investigated to find the optimal processing parameters to minimize weld‐line effects like reduced mechanical and/or optical performance. Injection molded test specimens of five polypropylene grades with different melt flow rates were characterized for their mechanical behavior and compared with equal‐shaped specimens with a colliding weld line in the middle of the specimen. For the production of these weld‐line specimens, a special mold was used and injection molding parameters were systematically varied, tensile (ISO 527‐2) and impact (ISO 179‐1/1eU) properties were measured, and statistical analyses were performed to gain insight on the correlation between melt flow rate and weld‐line behavior. It showed that mechanical properties of specimens with weld lines can be influenced by the processing parameters, but the effect is limited. Positive correlations were found between tool temperature and tensile modulus and strength. Polypropylene grades with low melt flow indexes seem to be more susceptible to weld‐line‐induced property reductions. In a second test series similar to the pure PP investigations, glass‐fiber‐ and talc‐filled PP were used to gain insight into the weld‐line behavior of PP composites. In addition to mechanical characterization, optical and scanning electron micrographs were taken of the weld‐line areas. It was found that the reinforcing particles align along the melt flow front in the weld‐line area. As a result, the mechanical performance of weld‐line specimens is poor. Injection molding parameters were found to have only a small effect.