Fiber reinforced composites offer exceptional directional mechanical properties, and combining their advantages with the capability of 3D printing has resulted in many innovative research fronts. This review aims to summarize the methods and findings of research conducted on 3D-printed carbon fiber reinforced composites. The review is focused on commercially available printers and filaments, as their results are reproducible and the findings can be applied to functional parts. As the process parameters can be readily changed in preparation of a 3D-printed part, it has been the focus of many studies. In addition to typical composite driving factors such as fiber orientation, fiber volume fraction and stacking sequence, printing parameters such as infill density, infill pattern, nozzle speed, layer thickness, built orientation, nozzle and bed temperatures have shown to influence mechanical properties. Due to the unique advantages of 3D printing, in addition to conventional unidirectional fiber orientation, concentric fiber rings have been used to optimize the mechanical performance of a part. This review surveys the literature in 3D printing of chopped and continuous carbon fiber composites to provide a reference for the state-of-the-art efforts, existing limitations and new research frontiers.

The main objective of this research is to prove the viability of obtaining magnesium (Mg) filled polylactic acid (PLA) biocomposites as filament feedstock for material extrusion-based additive manufacturing (AM). These materials can be used for medical applications, thus benefiting of all the advantages offered by AM technology in terms of design freedom and product customization. Filaments were produced from two PLA + magnesium + vitamin E (α-tocopherol) compositions and then used for manufacturing test samples and ACL (anterior cruciate ligament) screws on a low-cost 3D printer. Filaments and implant screws were characterized using SEM (scanning electron microscopy), FTIR (fourier transform infrared spectrometry), and DSC (differential scanning calorimetry) analysis. Although the filament manufacturing process could not ensure a uniform distribution of Mg particles within the PLA matrix, a good integration was noticed, probably due to the use of vitamin E as a precursor. The results also show that the composite biomaterials can ensure and maintain implant screws structural integrity during the additive manufacturing process.

In the context of the COVID-19 pandemic, shortwave ultraviolet radiation with wavelengths between 200 nm and 280 nm (UV-C) is seeing increased usage in the sterilization of medical equipment, appliances, and spaces due to its antimicrobial effect. During the first weeks of the pandemic, healthcare facilities experienced a shortage of personal protective equipment. This led to hospital technicians, private companies, and even members of the public to resort to 3D printing in order to produce fast, on-demand resources. This paper analyzes the effect of accelerated aging through prolonged exposure to UV-C on mechanical properties of parts 3D printed by material extrusion (MEX) from common polymers, such as polylactic acid (PLA) and polyethylene terephthalate-glycol (PETG). Samples 3D printed from these materials went through a 24-h UV-C exposure aging cycle and were then tested versus a control group for changes in mechanical properties. Both tensile and compressive strength were determined, as well as changes in material creep properties. Prolonged UV-C exposure reduced the mechanical properties of PLA by 6–8% and of PETG by over 30%. These findings are of practical importance for those interested in producing functional MEX parts intended to be sterilized using UV-C. Scanning electron microscopy (SEM) was performed in order to assess any changes in material structure.

This paper is a systematic review of the literature on 3D-printed anatomical replicas used as templates for precontouring the fixation plates in orthopedic surgery. Embase, PubMed, Cochrane, Scopus and Springer databases were consulted for information on design study, fracture anatomical location, number of patients, surgical technique, virtual modeling approach and 3D printing process. The initial search provided a total of 496 records. After removing the duplicates, the title and abstract screening, and applying exclusion criteria and citations searching, 30 papers were declared eligible and included in the final synthesis. Seven studies were identified as focusing on retrospective non-randomized series of clinical cases, while two papers presented randomized case control studies. Two main approaches were highlighted in developing 3D-printed anatomical models for precontouring fixation plates: (a.) medical reconstruction, virtual planning and fracture reduction followed by 3D printing the model; (b.) medical reconstruction followed by 3D printing the model of the mirrored uninjured side. Revised studies reported advantages such as surgical time and blood loss reduction, while the reduction quality is similar with that of the conventional surgery. During the last couple of years there was an increase in the number of studies focused on precontouring orthopedic plates using 3D printing technology. Three-dimensionally-printed templates for plate precontouring were mostly used for acetabular fractures. Knowledge on medical virtual modeling and reconstruction is mandatory.

Purpose: This paper aims to propose a new solution for producing customized three-dimensional (3D)-printed flat-shaped splints, which are then thermoformed to fit the patient’s hand. The splint design process is automated and is available to clinicians through an online application. Design/methodology/approach: Patient anthropometric data measured by clinicians are associated with variables of parametric 3D splint models. Once these variables are input by clinicians in the online app, customized stereo lithography (STL) files for both splint and half mold, in the case of the bi-material splint, are automatically generated and become available for download. Bi-materials splints are produced by a hybrid manufacturing process involving 3D printing and overmolding. Findings: This approach eliminates the need for 3D CAD-proficient clinicians, allows fast generation of customized splints, generates two-dimensional (2D) drawings of splints for verifying shape and dimensions before 3D printing and generates the STL files. Automation reduces splint design time and cost, while manufacturing time is diminished by 3D printing the splint in a flat position. Practical implications: The app could be used in clinical practice. It meets the demands of mass customization using 3D printing in a field where individualization is mandatory. The solution is scalable – it can be extended to other splint designs or to other limbs. 3D-printed tailored splints can offer improved wearing comfort and aesthetic appearance, while maintaining hand immobilization, allowing visually controlled follow-up for edema and rapidly observing the need for revision if necessary. Originality/value: An online application was developed for uploading patient measurements and downloading 2D drawings and STL files of customized splints. Different models of splints can be designed and included in the database as alternative variants. A method for producing bi-materials flat splints combining soft and rigid polymers represents another novelty of the research.