We report the design, fabrication, and characterization of novel, low-cost, and modular miniaturized nanofiber electrospinning sources for the scalable production of non-woven aligned nanofiber mats with low diameter variation. The devices are monolithic arrays of electrospinning emitters made via stereolithography; the emitters are arranged so each element has an independent line of sight to a rotating collector surface. Linear and zigzag emitter packing were evaluated using a PEO solution with the aim of maximizing the throughput of nanofibers with the smallest diameter and narrowest distribution. Current versus flowrate characterization of the devices showed that for a given flowrate a zigzag array produces more current per emitter than a linear array of the same emitter pitch and array size. In addition, the data demonstrate that larger and denser arrays have a net gain in flow rate per unit of active length. Visual inspection of the devices suggests uniform operation in devices with as many as 17 emitters with 300 μm inner diameter and 1.5 mm emitter gap. Well-aligned nanofiber mats were collected on a rotating drum and characterized; the 17-emitter device produced the same narrow nanofiber distribution (∼81 nm average diameter, ∼17 nm standard deviation) for all tested flow rates, which is strikingly different to the performance shown by 1-emitter sources where the average fiber diameter significantly increased and the statistics notably widened when the flowrate increases. Therefore, the data demonstrate that massively multiplexing the emitters is a viable approach to greatly increase the throughput of non-woven aligned nanofiber mats without sacrificing the statistics of the nanofibers generated. The production of dry nanofibers by the 17-emitter array is estimated at 33.0 mg min-1 (1.38 mg min-1 per mm of active length), which compares favorably with the reported multiplexed electrospinning arrays with emitters distributed along a line.

We used continuous flow micro-devices as bioreactors for the production of a glycosylated pharmaceutical product (a monoclonal antibody). We cultured CHO cells on the surface of PMMA/PDMS micro-channels that had been textured by micromachining and coated with fibronectin. Three different micro-channel geometries (a wavy channel, a zigzag channel, and a series of donut-shape reservoirs) were tested in a continuous flow regime in the range of 3 to 6 μL min⁻¹. Both the geometry of the micro-device and the flow rate had a significant effect on cell adhesion, cell proliferation, and monoclonal antibody production. The most efficient configuration was a series of donut-shaped reservoirs, which yielded mAb concentrations of 7.2 mg L⁻¹ at residence times lower than one minute and steady-state productivities above 9 mg mL⁻¹ min⁻¹. These rates are at about 3 orders of magnitude higher than those observed in suspended-cell stirred tank fed-batch bioreactors.

The growth of additive manufacturing processes has enabled the production of complex and smart structures. These fabrication techniques have led research efforts to focus on the application of cellular materials, which are known for their thermal and mechanical benefits. Herein, we studied the mechanical behavior of stainless-steel (AISI 316L) lattice structures both experimentally and computationally. The lattice architectures were body-centered cubic, hexagonal vertex centroid, and tetrahedron in two cell sizes and at two different rotation angles. A preliminary computational study assessed the deformation behavior of porous cylindrical samples under compression. After the simulation results, selected samples were manufactured via laser powder bed fusion. The results showed the effects of the pore architecture, unit cell size, and orientation on the reduction in the mechanical properties. The relative densities between 23% and 69% showed a decrease in the bulk material stiffness up to 93%. Furthermore, the different rotation angles resulted in a similar porosity level but different stiffnesses. The simulation analysis and experimental results indicate that the variation in the strut position with respect to the force affected the deformation mechanism. The tetrahedron unit cell showed the smallest variation in the elastic modulus and off-axis displacements due to the cell orientation. This study collected computational and experimental data for tuning the mechanical properties of lattice structures by changing the geometry, size, and orientation of the unit cell.

The understanding of dimensional variations produced by laser powder bed fusion is critical in components with small features and with dimensions close to the inherent limits of the process. In this context, two reference geometries were used: (a) straight walls to quantify dimensional relative error for small features and (b) a latticed neck region of a fatigued specimen (cubic and hexagonal cell design, with design strut sizes of 250 µm, 500 µm, and 1000 µm in cell size). Samples were fabricated out of AISI 316L stainless steel powder with different building orientations. The metrology techniques used were the following: focus variation microscopy, optical microscopy and micro-computed tomography. The straight wall characterization shows that built orientation does not influence dimensional relative error for walls with less than 750 µm. Acceptable dimensional relative errors (~ 2% to ~ 15%) are achieved only in walls with 750 µm in width of more. For lattice structures, the fine struts (250 µm) show a significant level of dimensional relative error (~ 5% to ~ 25%). This additive manufacturing process delivers more consistent dimensions for coarse struts (500 µm), with relative errors between ~ 2% and ~ 4%. All metrology techniques showed the same trends in terms of capturing the dimensional variations for fine and coarse struts.

The interplay between a prosthetic and tissue represents an important factor for the fixation of orthopedic implants. Laser texturing tests and electropolishing were performed on two materials used in the fabrication of medical devices, i.e., CoCr and Ti6Al4V-ELI alloys. The material surface was textured with a diode-pumped solid state (DPSS) laser and its effect on the surface quality and material modification, under different combinations of laser power and marking speed, were investigated. Our results indicate that an increment of energy per unit length causes an incremental trend in surface roughness parameters. Additionally, phase transformation on the surface of both alloys was achieved. Chemical analysis by energy dispersive X-ray spectrometer (EDX) shows the formation of (Co(Cr,Mo)) phase and the M₂₃C₆ precipitate on the CoCr surface; while quantitative analysis of the X-ray diffractometer (XRD) results demonstrates the oxidation of the Ti alloy with the formation of Ti₂O and Ti₆O from the reduction of the α-Ti phase. The behaviors were both related with an increase of the energy per unit length. Control of the final surface roughness was achieved by an electropolishing post-treatment, minimizing the as-treated values. After polishing, a reduction of surface roughness parameters was obtained in a range between 3% and 44%, while no changes in chemical composition or present phases were observed.

In this paper, we introduce the design and manufacturing process of a transtibial orthopedic implant. We used medical-grade polyurethane polymer resin to fabricate a 3D porous architected implant with tunable isotropy, employing a high-speed printing method known as Continuous Liquid Interface Production (CLIP). Our objective is to enhance the weight-bearing capabilities of the bone structures in the residual limb, thereby circumventing the traditional reliance on a natural bridge. To achieve a custom-made design, we acquire the topology and morphology of the residual limb as well as the bone structure of the tibia and fibula, utilizing computed tomography (CT) and high-resolution 3D scanning. We employed a dynamic topological optimization method, informed by gait cycle data, to effectively reduce the mass of the implant. This approach, which differs from conventional static methods, enables the quantification of variations in applied forces over time. Using the Euler-Lagrange energy approach, we propose the equations of motion for a homologous multibody model with three degrees of freedom. The versatility of the Solid Isotropic Material with Penalization (SIMP) method facilitates the integration of homogenization methods for microscale porous architectures into the optimized domain. The design of these porous architectures is based on a bias-driven tuning symmetry isotropy of a Triply Periodic Minimal Surface (Schwarz Primitive surface). The internal porosity of the structure significantly reduces weight without compromising the isotropic behavior of the implant.