Mika Salmi | Aalto University (original) (raw)
Papers by Mika Salmi
International Journal of Operations & Production Management, 2024
Purpose This works provides a thorough understanding of the challenges and opportunities associat... more Purpose
This works provides a thorough understanding of the challenges and opportunities associated with Additive Manufacturing (AM) adoption in the medical sector. Through this analysis, we aim to better understand when to adopt AM, how to do so, and how such adoption might change in the future.
Design/methodology/approach
This research first conducted a systematic literature review (SLR) to identify AM challenges and opportunities in the medical sector, which were then validated through a Delphi study. The 18 Delphi study participants were also asked to suggest countermeasures for the challenges and help identify future AM adoption scenarios. Finally, these findings were analyzed according to the ecosystem pie model to design an ecosystem model for AM in the medical sector.
Findings
Among the 13 challenges and 13 opportunities identified, the lack of a skilled workforce and the responsiveness achievable via AM were by far the most relevant challenge and opportunity. Moreover, the participants identified countermeasures for 10 challenges, as well as three future AM adoption scenarios. Finally, leveraging these findings, an ecosystem model was developed.
Originality/value
This work contributes to the limited understanding of the AM challenges and opportunities in the medical sector. It helps medical practitioners to better understand the challenges and opportunities associated with AM and AM manufacturers to better identify where to focus their R&D efforts and how this would impact future AM adoption levels. Furthermore, this work extends current theory supporting the design of an ecosystem model for AM in the medical sector following the ecosystem pie model.
Composites Part B: Engineering, 2025
he main objective of this study is to investigate, for the first time, the feasibility of 3d prin... more he main objective of this study is to investigate, for the first time, the feasibility of 3d printing a continuous carbon fiber (CCF) reinforced metal matrix composite using a cost-effective material extrusion (MEX) technology. Notably, this paper presents a detailed analysis of the microstructure and mechanical and physical properties of a bronze matrix composite reinforced with CCF. The results reveal that CCF significantly impedes the expected densification levels of the composite's structure, causing extensive gaps between the bronze particles. However, despite the high porosity level, the composite's electrical conductivity remains relatively high, demonstrating the limited negative impact of the CCF material on the composite's conductivity. Moreover, mechanical evaluations were performed through 3-point bending and tensile tests, highlighting the composite material's advantages and limitations. The results show that the composite material exhibits an improved yield stress of 76 %, increased ultimate tensile strength of 20 %, and an extended fracture strain of 30 %. However, the flexural strength decreases by 23 % due to the presence of massive gaps formed by CCF.
Advances in Production Management Systems. Production Management Systems for Volatile, Uncertain, Complex, and Ambiguous Environments. APMS 2024. IFIP Advances in Information and Communication Technology, 2024
This article reviews the growing literature on additive manufacturing (AM) operations management ... more This article reviews the growing literature on additive manufacturing (AM) operations management and sheds light on the emerging research areas in this field. As the AM use cases of final parts rapidly expand, it is essential to focus on the operations management of this technology and determine the primary current and future research streams. A literature study method is utilized to select, review, and categorize articles in the field of AM. The 108 articles selected after the initial evaluation were carefully examined and categorized. The selected papers evaluate AM from an operations management perspective. This article categorizes the body of knowledge studying the application and operations management of additive manufacturing into three categories: studies concerned with the industry's current state, forward-looking studies with a conceptual approach, and forward-looking papers with empirical grounding. Different AM processes studied are also considered. Our categorization showed that the latter category is still under-researched and presents an opportunity for future investigations. Moreover, six emerging streams of research in the third category were recognized. In addition to pointing out the areas of research that require more attention, this article aims to assist the researchers in better positioning their research.
Healthcare, 2024
3D printing has been adopted into routine use for certain medical applications, but more widespre... more 3D printing has been adopted into routine use for certain medical applications, but more widespread usage has been hindered by, among other things, unclear legislation. We performed an analysis, using legal doctrinal study and legal informatics, of relevant EU legislation and case law in four issues relevant to medical 3D printing (excluding bioprinting or pharmacoprinting): pre-market approval, post-market liability, intellectual property rights, and data protection. Several gaps and uncertainties in the current legislation and interpretations were identified. In particular, we regard the current EU regulatory framework to be quite limiting and inflexible, exemplifying a cautionary approach common in EU law. Though the need to establish high safety standards in order to protect patients as a disadvantaged population is understood, both legal uncertainties and overregulation are seen as harmful to innovation. Hence, more adaptive legislation is called for to ensure continuous innovation efforts and enhanced patient outcomes.
Logistics , 2024
Background: Additive manufacturing (AM) for patient-specific medical care products offers great o... more Background: Additive manufacturing (AM) for patient-specific medical care products offers great opportunities. However, evidence about the supply chain (SC) performance impact based on empirical data is limited. Methods: In this case study, we gathered real-life data about a traditional manufacturing orthopedic shoe SC and developed future scenarios in which AM is introduced at various points and with different degrees of penetration in the SC. Results: Presently, AM can only replace traditional manufacturing of tools and shoe components at a higher total cost. However, with maturing technology, the complete AM production of orthopedic shoes is expected to become feasible. Theoretically, that could disrupt existing SCs, eliminating 70% of the SC steps, improving SC lead time by 90%, and altering SC relations. However, certain thresholds currently prevent disruption. Specifically, the AM of complete orthopedic shoes has to become possible, manufacturing prices have to drop, and traditional craftsmanship has to be integrated into the digital product design. Conclusions: A framework for transition pathways, including directions for future research, is formed. Findings provide valuable insights for scholars and decision makers in the patient-specific products industry, health insurance providers, and healthcare policy makers to be better prepared by adjusting SC designs, relationships, and remuneration programs while AM technology develops towards maturity.
BMC Medical Education, 2024
Background In otosurgical training, cadaveric temporal bones are primarily used to provide a real... more Background In otosurgical training, cadaveric temporal bones are primarily used to provide a realistic tactile experience. However, using cadaveric temporal bones is challenging due to their limited availability, high cost, and potential for infection. Utilizing current three-dimensional (3D) technologies could overcome the limitations associated with cadaveric bones. This study focused on how a 3D-printed middle ear model can be used in otosurgical training. Methods A cadaveric temporal bone was imaged using microcomputed tomography (micro-CT) to generate a 3D model of the middle ear. The final model was printed from transparent photopolymers using a laser-based 3D printer (vat photopolymerization), yielding a 3D-printed phantom of the external ear canal and middle ear. The feasibility of this phantom for otosurgical training was evaluated through an ossiculoplasty simulation involving ten otosurgeons and ten otolaryngology-head and neck surgery (ORL-HNS) residents. The participants were tasked with drilling, scooping, and placing a 3D-printed partial ossicular replacement prosthesis (PORP). Following the simulation, a questionnaire was used to collect the participants' opinions and feedback. Results A transparent photopolymer was deemed suitable for both the middle ear phantom and PORP. The printing procedure was precise, and the anatomical landmarks were recognizable. Based on the evaluations, the phantom had realistic maneuverability, although the haptic feedback during drilling and scooping received some criticism from ORL-HNS residents. Both otosurgeons and ORL-HNS residents were optimistic about the application of these 3D-printed models as training tools. Conclusions The 3D-printed middle ear phantom and PORP used in this study can be used for low-threshold training in the future. The integration of 3D-printed models in conventional otosurgical training holds significant promise.
Materials, 2023
In this study, a set of 316 L stainless steel test specimens was additively manufactured by laser... more In this study, a set of 316 L stainless steel test specimens was additively manufactured by laser-based Powder Bed Fusion. The process parameters were varied for each specimen in terms of laser scan speed and laser power. The objective was to use a narrow band of parameters well inside the process window, demonstrating detailed parameter engineering for specialized additive manufacturing cases. The process variation was monitored using Optical Tomography to capture light emissions from the layer surfaces. Process emission values were stored in a statistical form. Micrographs were prepared and analyzed for defects using optical microscopy and image manipulation. The results of two data sources were compared to find correlations between lack of fusion, porosity, and layer-based energy emissions. A data comparison of Optical Tomography data and micrograph analyses shows that Optical Tomography can partially be used independently to develop new process parameters. The data show that the number of critical defects increases when the average Optical Tomography grey value passes a certain threshold. This finding can contribute to accelerating manufacturing parameter development and help meet the industrial need for agile component-specific parameter development.
Sensors and Actuators: A. Physical, 2024
3D-printing, also known as additive manufacturing, has enabled the production of dynamically shap... more 3D-printing, also known as additive manufacturing, has enabled the production of dynamically shaped objects
often customized for specific applications. Many applications, such as sensors in the aerospace industry, have
demanding mass and volume requirements or need to work in challenging environments that necessitate electronics
to be protected. The combination of 3D-printing and electronics could open up new applications not
feasible previously. We propose a novel manufacturing method capable of integrating a complex electric circuit
consisting of several, commonly available electronic components with a 3D-printed object. This is achieved using
a commercial printer and atomic layer deposition for coating. Various printable polymers and coatings were
tested to identify two polymers that could be printed into one object, allowing selective conductivity when
coated with conductive coating Selective conductivity is achieved when one polymer exhibits poorer and more
non-continuous coating growth compared to the other. The 3D-printed object’s three-dimensional shape and
details were used to create the electrical circuit and aid in achieving selective conductivity. A demonstration
consisting of an ultraviolet light (UV) sensor, based on an existing traditional circuit board, was replicated using
this method. The 3D-printed circuit was then tested by comparing its output with that of the original when placed
under the same UV-light source. The novel circuit output closely followed the original. The presented method can
combine an electric circuit with the dynamic capabilities of a 3D-printer, allowing for savings in existing applications
as well as new applications.
Virtual and Physical Prototyping, 2024
The objective of this study is to develop and evaluate self-sensing capabilities in additively ma... more The objective of this study is to develop and evaluate self-sensing capabilities in additively manufactured parts by embedding conductive elements that are copper and continuous carbon fiber. Two sets of test specimen were manufactured using a custom g-code on material extrusion-based Anisoprint A4 machine. Each set contained copper and continuous carbon fiber in an amorphous thermoplastic matrix. A tailor-made test setup was developed by improvising the American Society for Testing and Materials (ASTM D790) three-point loading system. Electrical resistance measurements were conducted under flexural loads to evaluate the selfsensing capability of each test specimen. The results confirmed that material extrusion technology can allow production of self-sensing parts. The electrical resistance increases linearly (Sensing tolerance <±2.6%, R 2 >93.8% p-value < 0.005), establishing a strong correlation with applied force and strain. The work allows for creating smart parts that can facilitate big data collection, analysis, and evidence-based decision-making for condition monitoring and preventive maintenance needed for Industry 4.0.
IOP Conference Series: Materials Science and Engineering, 2024
The aim of this study is to deploy machine learning (ML) classification methods to detect defecti... more The aim of this study is to deploy machine learning (ML) classification methods to detect defective regions in additive manufacturing, colloquially known as 3D printing, particularly for the laser-based powder bed fusion process. A custom-designed test specimen composed of 316L was manufactured using EOS M 290 machine. Multinomial logistic regression (MLR), artificial neural network (ANN), and convolutional neural network (CNN) classification techniques were applied to train the ML models using optical tomography infrared images of each additively manufactured layer of test specimen. Based on the trained MLR, ANN, and CNN classifiers, the ML models predict whether the manufactured layer is standard or defective, yielding five classes. Defective layers were classified into two classes for lack of fusion and two classes for keyhole porosity. The supervised approach yielded impeccable accuracy (>99%) for all three classification methods, however CNN inherited the highest degree of performance with 100% accuracy for independent test dataset unfamiliar to the model for unbiased evaluation. The high performance and low cost of computing observed in this work can have the potential to detect and eliminate defective regions by tuning the processing parameters in real time resulting in significantly decreased costs, lead-time, and waste. The proposed quality control can enable mass adoption of additive manufacturing technologies in a vast number of industries for critical components that are design-and shape-agnostic.
Progress in Additive Manufacturing , 2023
Shape memory polymer composites (SMPCs) have gained attention for their shape memory effects and ... more Shape memory polymer composites (SMPCs) have gained attention for their shape memory effects and wide-ranging applications. Understanding the bending shape recovery characteristics of 3D printed SMPCs is crucial for optimizing their performance. This study focuses on investigating the influence of different fiber orientations of continuous carbon fiber (CCF) in thermally stimulated SMPC. By controlling printing parameters and fiber orientation during the 3D printing process, we fabricate tailor-made rectangular composite test specimens. These specimens are subjected to controlled bending above the glass transition temperature of the polymer, inducing temporary deformation. The subsequent shape recovery process is carefully captured through high-speed video. Precise measurements of the bending curvature over time are obtained using the row-by-row image processing technique and analyzed. The shape recovery rate, shape recovery ratio, and shape fixity ratio of the test specimens were evaluated as a function of three CCF layout arrangements as well as fiber infill density embedded in Shape Memory Polymer (SMP) test specimens. The results revealed that the addition of CCF in the polymer matrix has a significant impact on shape memory behavior. Vertically aligned CCF in the SMP matrix improves the shape recovery ratio (92.97% compared to 78.77% of the pure SMP sample), while horizontal alignment of CCF ensures maximum shape fixity ratio (91.78% compared to 66.22% of the pure SMP sample). The cross-aligned CCF sample provides good recovery as well as fixity values. Further, it was observed that the horizontal alignment of CCF yields the fastest recovery performance. The outcome confirms that optimizing the fiber orientation enhances shape memory performance. Also, 40% of fiber infill density had greater shape fixity and overall recovery performance when compared to 30% and 50%. These findings have implications for tailored and high-performance SMPCs in biomedical devices, aerospace components, and robotics. Understanding temporal curvature behavior enables optimizing the design of materials with precise control over shape recovery. This research contributes to the design and optimization of SMPCs for diverse applications.
Journal of Mechanical Science and Technology , 2023
Additive manufacturing has shown potential for spare parts but still faces challenges related to ... more Additive manufacturing has shown potential for spare parts but still faces challenges related to material availability, quality, part size, cost, and pre-and post-processing operations. In literature, most studies focus on a single use case. In contrast, reviews focus on the applications of additive manufacturing technology from a general perspective rather than on specific additive manufacturing processes used for spare parts manufacture. This study attempts to fill this gap by considering the additive manufacturing of spare parts and processes that may have novel research possibilities in the future. It is revealed that material jetting and binder jetting are not commonly used in end-use parts, sheet lamination is rarely used at all, and directed energy deposition is used in repairing spare parts. Powder bed fusion and material extrusion are used in most industries. Further developmental efforts on binder jetting and material extrusion would allow for greater possibilities in future applications.
Additive Manufacturing , 2023
The metal vat photopolymerization technique (MVP) has high potential for metal part production be... more The metal vat photopolymerization technique (MVP) has high potential for metal part production because of its high accuracy, speed, and flexibility. However, low density, poor mechanical properties, and effects of sintering parameters on the properties are some of the challenges in MVP. This paper is the first to investigate the possibility of producing a NiTiCu metal alloy using VP from Ni, Ti, and Cu elemental and mechanically alloyed powders. The effect of particle size distribution and solid content on the physical and mechanical properties is also studied and compared. The results indicate that all three elements are homogeneously distributed in the whole print without premixing the powders, which considerably reduces processing time. Finer particle size and higher solid content also improve densification degree, hardness, flexural strength, and surface quality of the final parts. The measured surface roughness (R a) of NiTiCu was 6.42 µm and 10.31 µm for milled and elemental powders, respectively. However, the mechanical properties of NiTiCu produced by VP in this study remain insufficient and in need of further improvement.
In the last years, Additive manufacturing (AM) has gained increasing interest among practitioners... more In the last years, Additive manufacturing (AM) has gained increasing interest among practitioners in manufacturing personalized medical products. Researchers have consequently aligned to this increasing interest from practice, trying to support the development of AM for personalized medical products. However, researchers are currently overlooking one of the main aspects that would ensure the successful development of AM in the medical sector: the supply chain configuration. Practitioners are left alone configuring their supply, such as centralized or decentralized production, what to insource and what to outsource, etc. Some guidelines to support them in their decisions are hence needed. However, before doing that, it is necessary to understand the possible business models that can be adopted. In this work, we aim to do so. Specifically, we have conducted a narrative literature review, interviews and a workshop. Nine possible business models, three current ones and six future ones were identified. In addition, to describe the different business models, we have also identified their main challenges. The study represents preliminary work necessary to support the development of AM for personalized medical products in terms of business models and supply chain configurations.
International Journal of Bioprinting, 2023
Despite advances in prosthesis materials, operating microscopes and surgical techniques during th... more Despite advances in prosthesis materials, operating microscopes and surgical techniques during the last 50 years, long-lasting hearing improvement remains a challenge in ossicular chain reconstruction. Failures in the reconstruction are mainly due to inadequate length or shape of the prosthesis, or defects in the surgical procedure. 3D-printed middle ear prosthesis might offer a solution to individualize treatment and obtain better results. The aim of the study was to study the possibilities and limitations of 3D-printed middle ear prostheses. Design of the 3D-printed prosthesis was inspired by a commercial titanium partial ossicular replacement prosthesis. 3D models of different lengths (1.5-3.0 mm) were created with Solidworks 2019-2021 software. The prostheses were 3D-printed with vat photopolymerization using liquid photopolymer Clear V4. Accuracy and reproducibility of 3D printing were evaluated with micro-CT imaging. The acoustical performance of the prostheses was determined in cadaver temporal bones with laser Doppler vibrometry. In this paper, we present an outline of individualized middle ear prosthesis manufacturing. 3D printing accuracy was excellent when comparing dimensions of the 3D-printed prostheses and their 3D models. Reproducibility of 3D printing was good if the diameter of the prosthesis shaft was 0.6 mm. 3D-printed partial ossicular replacement prostheses were easy to manipulate during surgery even though they were a bit stiffer and less flexible than conventional titanium prostheses. Their acoustical performance was similar to that of a commercial titanium partial ossicular replacement prosthesis. It is possible to 3D print functional individualized middle ear prostheses made of liquid photopolymer with good accuracy and reproducibility. These prostheses are currently suitable for otosurgical training. Further research is needed to explore their usability in a clinical setting. In the future, 3D printing of individualized middle ear prostheses may provide better audiological outcomes for patients.
Frontiers in Bioengineering and Biotechnology, 2023
Introduction: 3D printing has quickly found many applications in medicine. However, as with any n... more Introduction: 3D printing has quickly found many applications in medicine. However, as with any new technology the regulatory landscape is struggling to stay abreast. Unclear legislation or lack of legislation has been suggested as being one hindrance for wide-scale adoption.
Methods: A scoping review was performed in PubMed, Web of Science, SCOPUS and Westlaw International to identify articles dealing with legal issues in medical 3D printing.
Results: Thirty-four articles fulfilling inclusion criteria were identified in medical/technical databases and fifteen in the legal database. The majority of articles dealt with the USA, while the EU was also prominently represented. Some common unresolved legal issues were identified, among them terminological confusion between custom-made and patient-matched devices, lack of specific legislation for patient-matched products, and the undefined legal role of CAD files both from a liability and from an intellectual property standpoint. Data protection was mentioned only in two papers and seems an underexplored topic.
Conclusion: In this scoping review, several relevant articles and several common unresolved legal issues were identified including a need for terminological uniformity in medical 3D printing. The results of this work are planned to inform our own deeper legal analysis of these issues in the future.
Proceedings of the 20th European Conference on Composite Materials - Composites Meet Sustainability, 2022
Additive manufacturing (AM) has shown to be a promising method for creating high-performance plas... more Additive manufacturing (AM) has shown to be a promising method for creating high-performance
plastic components. In space, harsh environmental conditions such as vacuum
ultraviolet radiation and significant temperature changes cause the degradation of polymers and
static electricity buildup on the surface of non-conductive components.
This study explores geostationary orbit communication-satellite parts additively manufactured
using doped polyether ether ketone (PEEK). Several spacecraft parts were selected for detailed
redesign and additive manufacturing. These parts are commonly used in communication
satellites and belong to secondary structures that need not withstand heavy forces.
The effects of the space environment on the doped PEEK material and its properties were studied
in ground-based laboratories. The printed parts were mechanically and functionally tested. Low mass
space-grade components can be made with this method and material combination while
conforming with the stiffness requirements for secondary spacecraft structures. This
manufacturing method aims to achieve mass savings of 50% compared to metallic baselines.
The analysis showed that that printing parameters used in the fused filament fabrication (FFF)
process significantly affect the mechanical performance of the parts. Moreover, the high
strength and stiffness of the FFF-printed carbon-fibre doped PEEK brackets was found to make
them ideal for joints used in spacecraft honeycomb panel structures, enabling up to 25–50%
savings in bracket mass. Overall, the used FFF manufacturing method enables fast, and cost effective
low batch-size production runs.
Additive Manufacturing, 2023
Laser powder bed fusion (LPBF) has become an established method for manufacturing end-use metal c... more Laser powder bed fusion (LPBF) has become an established method for manufacturing end-use metal components. Exploiting the geometric freedom of additive manufacturing (AM) offers broad possibilities for part optimization and enables performance enhancements across industry sectors. However, part shape and feature size have been found to locally affect residual stresses, melt pool cooling rates, microstructure, and thus the mechanical properties of components. Even though the mesoscale structure can locally induce microstructural changes, there are no prior studies on how it influences corrosion. Using AM-produced, optimized parts in critical applications necessitates a better understanding of their long-term performance. In this study, lattice structures were used to probe the influence of feature size and shape on corrosion susceptibility and its spatial localization. The susceptibility of submillimeter LPBF-fabricated 316L stainless steel lattice structures to corrosion was investigated by conducting a 21-day immersion corrosion test in an aqueous 3.5 wt% NaCl solution. Schoen gyroid and Schwarz diamond triply periodic minimal surface lattices were manufactured with three unit cell sizes and wall thicknesses (0.867, 0.515, and 0.323 mm). The nominal surface and cross-sectional areas were the same for the two geometries. X-ray microcomputed tomography (microCT) scans before and after the corrosion test were compared for volumetric losses. In addition, the mechanical properties and microstructure of the samples were evaluated. As part of the study, a workflow to register, index, and analyze volumetric changes of consecutive microCT image stacks was developed. The reported method is applicable to any time-lapse studies with microCT. Three out of five of the 0.323 mm wall thickness lattices displayed visually aggressive pitting. Based on the microcomputed tomography data, the mass losses were localized either in the entrapped powder particles or partially melted surface globules. Corrosion did not occur in the dense base material. The total mass losses ranged from 8 to 19 mg. Despite visual indications to support a higher corrosion susceptibility for the smallest lattice sizes, the mass loss values did not confirm this conclusion. The tensile test results did not provide any clear indications of latent corrosion effects on mechanical properties.
International Journal of Operations & Production Management, 2024
Purpose This works provides a thorough understanding of the challenges and opportunities associat... more Purpose
This works provides a thorough understanding of the challenges and opportunities associated with Additive Manufacturing (AM) adoption in the medical sector. Through this analysis, we aim to better understand when to adopt AM, how to do so, and how such adoption might change in the future.
Design/methodology/approach
This research first conducted a systematic literature review (SLR) to identify AM challenges and opportunities in the medical sector, which were then validated through a Delphi study. The 18 Delphi study participants were also asked to suggest countermeasures for the challenges and help identify future AM adoption scenarios. Finally, these findings were analyzed according to the ecosystem pie model to design an ecosystem model for AM in the medical sector.
Findings
Among the 13 challenges and 13 opportunities identified, the lack of a skilled workforce and the responsiveness achievable via AM were by far the most relevant challenge and opportunity. Moreover, the participants identified countermeasures for 10 challenges, as well as three future AM adoption scenarios. Finally, leveraging these findings, an ecosystem model was developed.
Originality/value
This work contributes to the limited understanding of the AM challenges and opportunities in the medical sector. It helps medical practitioners to better understand the challenges and opportunities associated with AM and AM manufacturers to better identify where to focus their R&D efforts and how this would impact future AM adoption levels. Furthermore, this work extends current theory supporting the design of an ecosystem model for AM in the medical sector following the ecosystem pie model.
Composites Part B: Engineering, 2025
he main objective of this study is to investigate, for the first time, the feasibility of 3d prin... more he main objective of this study is to investigate, for the first time, the feasibility of 3d printing a continuous carbon fiber (CCF) reinforced metal matrix composite using a cost-effective material extrusion (MEX) technology. Notably, this paper presents a detailed analysis of the microstructure and mechanical and physical properties of a bronze matrix composite reinforced with CCF. The results reveal that CCF significantly impedes the expected densification levels of the composite's structure, causing extensive gaps between the bronze particles. However, despite the high porosity level, the composite's electrical conductivity remains relatively high, demonstrating the limited negative impact of the CCF material on the composite's conductivity. Moreover, mechanical evaluations were performed through 3-point bending and tensile tests, highlighting the composite material's advantages and limitations. The results show that the composite material exhibits an improved yield stress of 76 %, increased ultimate tensile strength of 20 %, and an extended fracture strain of 30 %. However, the flexural strength decreases by 23 % due to the presence of massive gaps formed by CCF.
Advances in Production Management Systems. Production Management Systems for Volatile, Uncertain, Complex, and Ambiguous Environments. APMS 2024. IFIP Advances in Information and Communication Technology, 2024
This article reviews the growing literature on additive manufacturing (AM) operations management ... more This article reviews the growing literature on additive manufacturing (AM) operations management and sheds light on the emerging research areas in this field. As the AM use cases of final parts rapidly expand, it is essential to focus on the operations management of this technology and determine the primary current and future research streams. A literature study method is utilized to select, review, and categorize articles in the field of AM. The 108 articles selected after the initial evaluation were carefully examined and categorized. The selected papers evaluate AM from an operations management perspective. This article categorizes the body of knowledge studying the application and operations management of additive manufacturing into three categories: studies concerned with the industry's current state, forward-looking studies with a conceptual approach, and forward-looking papers with empirical grounding. Different AM processes studied are also considered. Our categorization showed that the latter category is still under-researched and presents an opportunity for future investigations. Moreover, six emerging streams of research in the third category were recognized. In addition to pointing out the areas of research that require more attention, this article aims to assist the researchers in better positioning their research.
Healthcare, 2024
3D printing has been adopted into routine use for certain medical applications, but more widespre... more 3D printing has been adopted into routine use for certain medical applications, but more widespread usage has been hindered by, among other things, unclear legislation. We performed an analysis, using legal doctrinal study and legal informatics, of relevant EU legislation and case law in four issues relevant to medical 3D printing (excluding bioprinting or pharmacoprinting): pre-market approval, post-market liability, intellectual property rights, and data protection. Several gaps and uncertainties in the current legislation and interpretations were identified. In particular, we regard the current EU regulatory framework to be quite limiting and inflexible, exemplifying a cautionary approach common in EU law. Though the need to establish high safety standards in order to protect patients as a disadvantaged population is understood, both legal uncertainties and overregulation are seen as harmful to innovation. Hence, more adaptive legislation is called for to ensure continuous innovation efforts and enhanced patient outcomes.
Logistics , 2024
Background: Additive manufacturing (AM) for patient-specific medical care products offers great o... more Background: Additive manufacturing (AM) for patient-specific medical care products offers great opportunities. However, evidence about the supply chain (SC) performance impact based on empirical data is limited. Methods: In this case study, we gathered real-life data about a traditional manufacturing orthopedic shoe SC and developed future scenarios in which AM is introduced at various points and with different degrees of penetration in the SC. Results: Presently, AM can only replace traditional manufacturing of tools and shoe components at a higher total cost. However, with maturing technology, the complete AM production of orthopedic shoes is expected to become feasible. Theoretically, that could disrupt existing SCs, eliminating 70% of the SC steps, improving SC lead time by 90%, and altering SC relations. However, certain thresholds currently prevent disruption. Specifically, the AM of complete orthopedic shoes has to become possible, manufacturing prices have to drop, and traditional craftsmanship has to be integrated into the digital product design. Conclusions: A framework for transition pathways, including directions for future research, is formed. Findings provide valuable insights for scholars and decision makers in the patient-specific products industry, health insurance providers, and healthcare policy makers to be better prepared by adjusting SC designs, relationships, and remuneration programs while AM technology develops towards maturity.
BMC Medical Education, 2024
Background In otosurgical training, cadaveric temporal bones are primarily used to provide a real... more Background In otosurgical training, cadaveric temporal bones are primarily used to provide a realistic tactile experience. However, using cadaveric temporal bones is challenging due to their limited availability, high cost, and potential for infection. Utilizing current three-dimensional (3D) technologies could overcome the limitations associated with cadaveric bones. This study focused on how a 3D-printed middle ear model can be used in otosurgical training. Methods A cadaveric temporal bone was imaged using microcomputed tomography (micro-CT) to generate a 3D model of the middle ear. The final model was printed from transparent photopolymers using a laser-based 3D printer (vat photopolymerization), yielding a 3D-printed phantom of the external ear canal and middle ear. The feasibility of this phantom for otosurgical training was evaluated through an ossiculoplasty simulation involving ten otosurgeons and ten otolaryngology-head and neck surgery (ORL-HNS) residents. The participants were tasked with drilling, scooping, and placing a 3D-printed partial ossicular replacement prosthesis (PORP). Following the simulation, a questionnaire was used to collect the participants' opinions and feedback. Results A transparent photopolymer was deemed suitable for both the middle ear phantom and PORP. The printing procedure was precise, and the anatomical landmarks were recognizable. Based on the evaluations, the phantom had realistic maneuverability, although the haptic feedback during drilling and scooping received some criticism from ORL-HNS residents. Both otosurgeons and ORL-HNS residents were optimistic about the application of these 3D-printed models as training tools. Conclusions The 3D-printed middle ear phantom and PORP used in this study can be used for low-threshold training in the future. The integration of 3D-printed models in conventional otosurgical training holds significant promise.
Materials, 2023
In this study, a set of 316 L stainless steel test specimens was additively manufactured by laser... more In this study, a set of 316 L stainless steel test specimens was additively manufactured by laser-based Powder Bed Fusion. The process parameters were varied for each specimen in terms of laser scan speed and laser power. The objective was to use a narrow band of parameters well inside the process window, demonstrating detailed parameter engineering for specialized additive manufacturing cases. The process variation was monitored using Optical Tomography to capture light emissions from the layer surfaces. Process emission values were stored in a statistical form. Micrographs were prepared and analyzed for defects using optical microscopy and image manipulation. The results of two data sources were compared to find correlations between lack of fusion, porosity, and layer-based energy emissions. A data comparison of Optical Tomography data and micrograph analyses shows that Optical Tomography can partially be used independently to develop new process parameters. The data show that the number of critical defects increases when the average Optical Tomography grey value passes a certain threshold. This finding can contribute to accelerating manufacturing parameter development and help meet the industrial need for agile component-specific parameter development.
Sensors and Actuators: A. Physical, 2024
3D-printing, also known as additive manufacturing, has enabled the production of dynamically shap... more 3D-printing, also known as additive manufacturing, has enabled the production of dynamically shaped objects
often customized for specific applications. Many applications, such as sensors in the aerospace industry, have
demanding mass and volume requirements or need to work in challenging environments that necessitate electronics
to be protected. The combination of 3D-printing and electronics could open up new applications not
feasible previously. We propose a novel manufacturing method capable of integrating a complex electric circuit
consisting of several, commonly available electronic components with a 3D-printed object. This is achieved using
a commercial printer and atomic layer deposition for coating. Various printable polymers and coatings were
tested to identify two polymers that could be printed into one object, allowing selective conductivity when
coated with conductive coating Selective conductivity is achieved when one polymer exhibits poorer and more
non-continuous coating growth compared to the other. The 3D-printed object’s three-dimensional shape and
details were used to create the electrical circuit and aid in achieving selective conductivity. A demonstration
consisting of an ultraviolet light (UV) sensor, based on an existing traditional circuit board, was replicated using
this method. The 3D-printed circuit was then tested by comparing its output with that of the original when placed
under the same UV-light source. The novel circuit output closely followed the original. The presented method can
combine an electric circuit with the dynamic capabilities of a 3D-printer, allowing for savings in existing applications
as well as new applications.
Virtual and Physical Prototyping, 2024
The objective of this study is to develop and evaluate self-sensing capabilities in additively ma... more The objective of this study is to develop and evaluate self-sensing capabilities in additively manufactured parts by embedding conductive elements that are copper and continuous carbon fiber. Two sets of test specimen were manufactured using a custom g-code on material extrusion-based Anisoprint A4 machine. Each set contained copper and continuous carbon fiber in an amorphous thermoplastic matrix. A tailor-made test setup was developed by improvising the American Society for Testing and Materials (ASTM D790) three-point loading system. Electrical resistance measurements were conducted under flexural loads to evaluate the selfsensing capability of each test specimen. The results confirmed that material extrusion technology can allow production of self-sensing parts. The electrical resistance increases linearly (Sensing tolerance <±2.6%, R 2 >93.8% p-value < 0.005), establishing a strong correlation with applied force and strain. The work allows for creating smart parts that can facilitate big data collection, analysis, and evidence-based decision-making for condition monitoring and preventive maintenance needed for Industry 4.0.
IOP Conference Series: Materials Science and Engineering, 2024
The aim of this study is to deploy machine learning (ML) classification methods to detect defecti... more The aim of this study is to deploy machine learning (ML) classification methods to detect defective regions in additive manufacturing, colloquially known as 3D printing, particularly for the laser-based powder bed fusion process. A custom-designed test specimen composed of 316L was manufactured using EOS M 290 machine. Multinomial logistic regression (MLR), artificial neural network (ANN), and convolutional neural network (CNN) classification techniques were applied to train the ML models using optical tomography infrared images of each additively manufactured layer of test specimen. Based on the trained MLR, ANN, and CNN classifiers, the ML models predict whether the manufactured layer is standard or defective, yielding five classes. Defective layers were classified into two classes for lack of fusion and two classes for keyhole porosity. The supervised approach yielded impeccable accuracy (>99%) for all three classification methods, however CNN inherited the highest degree of performance with 100% accuracy for independent test dataset unfamiliar to the model for unbiased evaluation. The high performance and low cost of computing observed in this work can have the potential to detect and eliminate defective regions by tuning the processing parameters in real time resulting in significantly decreased costs, lead-time, and waste. The proposed quality control can enable mass adoption of additive manufacturing technologies in a vast number of industries for critical components that are design-and shape-agnostic.
Progress in Additive Manufacturing , 2023
Shape memory polymer composites (SMPCs) have gained attention for their shape memory effects and ... more Shape memory polymer composites (SMPCs) have gained attention for their shape memory effects and wide-ranging applications. Understanding the bending shape recovery characteristics of 3D printed SMPCs is crucial for optimizing their performance. This study focuses on investigating the influence of different fiber orientations of continuous carbon fiber (CCF) in thermally stimulated SMPC. By controlling printing parameters and fiber orientation during the 3D printing process, we fabricate tailor-made rectangular composite test specimens. These specimens are subjected to controlled bending above the glass transition temperature of the polymer, inducing temporary deformation. The subsequent shape recovery process is carefully captured through high-speed video. Precise measurements of the bending curvature over time are obtained using the row-by-row image processing technique and analyzed. The shape recovery rate, shape recovery ratio, and shape fixity ratio of the test specimens were evaluated as a function of three CCF layout arrangements as well as fiber infill density embedded in Shape Memory Polymer (SMP) test specimens. The results revealed that the addition of CCF in the polymer matrix has a significant impact on shape memory behavior. Vertically aligned CCF in the SMP matrix improves the shape recovery ratio (92.97% compared to 78.77% of the pure SMP sample), while horizontal alignment of CCF ensures maximum shape fixity ratio (91.78% compared to 66.22% of the pure SMP sample). The cross-aligned CCF sample provides good recovery as well as fixity values. Further, it was observed that the horizontal alignment of CCF yields the fastest recovery performance. The outcome confirms that optimizing the fiber orientation enhances shape memory performance. Also, 40% of fiber infill density had greater shape fixity and overall recovery performance when compared to 30% and 50%. These findings have implications for tailored and high-performance SMPCs in biomedical devices, aerospace components, and robotics. Understanding temporal curvature behavior enables optimizing the design of materials with precise control over shape recovery. This research contributes to the design and optimization of SMPCs for diverse applications.
Journal of Mechanical Science and Technology , 2023
Additive manufacturing has shown potential for spare parts but still faces challenges related to ... more Additive manufacturing has shown potential for spare parts but still faces challenges related to material availability, quality, part size, cost, and pre-and post-processing operations. In literature, most studies focus on a single use case. In contrast, reviews focus on the applications of additive manufacturing technology from a general perspective rather than on specific additive manufacturing processes used for spare parts manufacture. This study attempts to fill this gap by considering the additive manufacturing of spare parts and processes that may have novel research possibilities in the future. It is revealed that material jetting and binder jetting are not commonly used in end-use parts, sheet lamination is rarely used at all, and directed energy deposition is used in repairing spare parts. Powder bed fusion and material extrusion are used in most industries. Further developmental efforts on binder jetting and material extrusion would allow for greater possibilities in future applications.
Additive Manufacturing , 2023
The metal vat photopolymerization technique (MVP) has high potential for metal part production be... more The metal vat photopolymerization technique (MVP) has high potential for metal part production because of its high accuracy, speed, and flexibility. However, low density, poor mechanical properties, and effects of sintering parameters on the properties are some of the challenges in MVP. This paper is the first to investigate the possibility of producing a NiTiCu metal alloy using VP from Ni, Ti, and Cu elemental and mechanically alloyed powders. The effect of particle size distribution and solid content on the physical and mechanical properties is also studied and compared. The results indicate that all three elements are homogeneously distributed in the whole print without premixing the powders, which considerably reduces processing time. Finer particle size and higher solid content also improve densification degree, hardness, flexural strength, and surface quality of the final parts. The measured surface roughness (R a) of NiTiCu was 6.42 µm and 10.31 µm for milled and elemental powders, respectively. However, the mechanical properties of NiTiCu produced by VP in this study remain insufficient and in need of further improvement.
In the last years, Additive manufacturing (AM) has gained increasing interest among practitioners... more In the last years, Additive manufacturing (AM) has gained increasing interest among practitioners in manufacturing personalized medical products. Researchers have consequently aligned to this increasing interest from practice, trying to support the development of AM for personalized medical products. However, researchers are currently overlooking one of the main aspects that would ensure the successful development of AM in the medical sector: the supply chain configuration. Practitioners are left alone configuring their supply, such as centralized or decentralized production, what to insource and what to outsource, etc. Some guidelines to support them in their decisions are hence needed. However, before doing that, it is necessary to understand the possible business models that can be adopted. In this work, we aim to do so. Specifically, we have conducted a narrative literature review, interviews and a workshop. Nine possible business models, three current ones and six future ones were identified. In addition, to describe the different business models, we have also identified their main challenges. The study represents preliminary work necessary to support the development of AM for personalized medical products in terms of business models and supply chain configurations.
International Journal of Bioprinting, 2023
Despite advances in prosthesis materials, operating microscopes and surgical techniques during th... more Despite advances in prosthesis materials, operating microscopes and surgical techniques during the last 50 years, long-lasting hearing improvement remains a challenge in ossicular chain reconstruction. Failures in the reconstruction are mainly due to inadequate length or shape of the prosthesis, or defects in the surgical procedure. 3D-printed middle ear prosthesis might offer a solution to individualize treatment and obtain better results. The aim of the study was to study the possibilities and limitations of 3D-printed middle ear prostheses. Design of the 3D-printed prosthesis was inspired by a commercial titanium partial ossicular replacement prosthesis. 3D models of different lengths (1.5-3.0 mm) were created with Solidworks 2019-2021 software. The prostheses were 3D-printed with vat photopolymerization using liquid photopolymer Clear V4. Accuracy and reproducibility of 3D printing were evaluated with micro-CT imaging. The acoustical performance of the prostheses was determined in cadaver temporal bones with laser Doppler vibrometry. In this paper, we present an outline of individualized middle ear prosthesis manufacturing. 3D printing accuracy was excellent when comparing dimensions of the 3D-printed prostheses and their 3D models. Reproducibility of 3D printing was good if the diameter of the prosthesis shaft was 0.6 mm. 3D-printed partial ossicular replacement prostheses were easy to manipulate during surgery even though they were a bit stiffer and less flexible than conventional titanium prostheses. Their acoustical performance was similar to that of a commercial titanium partial ossicular replacement prosthesis. It is possible to 3D print functional individualized middle ear prostheses made of liquid photopolymer with good accuracy and reproducibility. These prostheses are currently suitable for otosurgical training. Further research is needed to explore their usability in a clinical setting. In the future, 3D printing of individualized middle ear prostheses may provide better audiological outcomes for patients.
Frontiers in Bioengineering and Biotechnology, 2023
Introduction: 3D printing has quickly found many applications in medicine. However, as with any n... more Introduction: 3D printing has quickly found many applications in medicine. However, as with any new technology the regulatory landscape is struggling to stay abreast. Unclear legislation or lack of legislation has been suggested as being one hindrance for wide-scale adoption.
Methods: A scoping review was performed in PubMed, Web of Science, SCOPUS and Westlaw International to identify articles dealing with legal issues in medical 3D printing.
Results: Thirty-four articles fulfilling inclusion criteria were identified in medical/technical databases and fifteen in the legal database. The majority of articles dealt with the USA, while the EU was also prominently represented. Some common unresolved legal issues were identified, among them terminological confusion between custom-made and patient-matched devices, lack of specific legislation for patient-matched products, and the undefined legal role of CAD files both from a liability and from an intellectual property standpoint. Data protection was mentioned only in two papers and seems an underexplored topic.
Conclusion: In this scoping review, several relevant articles and several common unresolved legal issues were identified including a need for terminological uniformity in medical 3D printing. The results of this work are planned to inform our own deeper legal analysis of these issues in the future.
Proceedings of the 20th European Conference on Composite Materials - Composites Meet Sustainability, 2022
Additive manufacturing (AM) has shown to be a promising method for creating high-performance plas... more Additive manufacturing (AM) has shown to be a promising method for creating high-performance
plastic components. In space, harsh environmental conditions such as vacuum
ultraviolet radiation and significant temperature changes cause the degradation of polymers and
static electricity buildup on the surface of non-conductive components.
This study explores geostationary orbit communication-satellite parts additively manufactured
using doped polyether ether ketone (PEEK). Several spacecraft parts were selected for detailed
redesign and additive manufacturing. These parts are commonly used in communication
satellites and belong to secondary structures that need not withstand heavy forces.
The effects of the space environment on the doped PEEK material and its properties were studied
in ground-based laboratories. The printed parts were mechanically and functionally tested. Low mass
space-grade components can be made with this method and material combination while
conforming with the stiffness requirements for secondary spacecraft structures. This
manufacturing method aims to achieve mass savings of 50% compared to metallic baselines.
The analysis showed that that printing parameters used in the fused filament fabrication (FFF)
process significantly affect the mechanical performance of the parts. Moreover, the high
strength and stiffness of the FFF-printed carbon-fibre doped PEEK brackets was found to make
them ideal for joints used in spacecraft honeycomb panel structures, enabling up to 25–50%
savings in bracket mass. Overall, the used FFF manufacturing method enables fast, and cost effective
low batch-size production runs.
Additive Manufacturing, 2023
Laser powder bed fusion (LPBF) has become an established method for manufacturing end-use metal c... more Laser powder bed fusion (LPBF) has become an established method for manufacturing end-use metal components. Exploiting the geometric freedom of additive manufacturing (AM) offers broad possibilities for part optimization and enables performance enhancements across industry sectors. However, part shape and feature size have been found to locally affect residual stresses, melt pool cooling rates, microstructure, and thus the mechanical properties of components. Even though the mesoscale structure can locally induce microstructural changes, there are no prior studies on how it influences corrosion. Using AM-produced, optimized parts in critical applications necessitates a better understanding of their long-term performance. In this study, lattice structures were used to probe the influence of feature size and shape on corrosion susceptibility and its spatial localization. The susceptibility of submillimeter LPBF-fabricated 316L stainless steel lattice structures to corrosion was investigated by conducting a 21-day immersion corrosion test in an aqueous 3.5 wt% NaCl solution. Schoen gyroid and Schwarz diamond triply periodic minimal surface lattices were manufactured with three unit cell sizes and wall thicknesses (0.867, 0.515, and 0.323 mm). The nominal surface and cross-sectional areas were the same for the two geometries. X-ray microcomputed tomography (microCT) scans before and after the corrosion test were compared for volumetric losses. In addition, the mechanical properties and microstructure of the samples were evaluated. As part of the study, a workflow to register, index, and analyze volumetric changes of consecutive microCT image stacks was developed. The reported method is applicable to any time-lapse studies with microCT. Three out of five of the 0.323 mm wall thickness lattices displayed visually aggressive pitting. Based on the microcomputed tomography data, the mass losses were localized either in the entrapped powder particles or partially melted surface globules. Corrosion did not occur in the dense base material. The total mass losses ranged from 8 to 19 mg. Despite visual indications to support a higher corrosion susceptibility for the smallest lattice sizes, the mass loss values did not confirm this conclusion. The tensile test results did not provide any clear indications of latent corrosion effects on mechanical properties.
Additive manufacturing (AM) or, more commonly, 3D printing has grown in double digits in past yea... more Additive manufacturing (AM) or, more commonly, 3D printing has grown in double digits in past years. It has shown its potential example in the medical, automotive, aerospace, and spare part sectors. Personal manufacturing, complex and optimized parts, short series manufacturing and local on-demand manufacturing are some of the current benefits. The development of new materials and equipment has opened up new application possibilities, and equipment is quicker and cheaper using the new materials launched by vendors and material developers. AM has become more critical for the industry but also for academics. Since AM offers more design freedom than any other manufacturing process, it provides designers with a new challenge to design better and more efficient products.
The objective of this Special Issue was to provide a forum for researchers and practitioners to exchange their latest achievements and to identify critical issues and challenges for future investigations of the design and applications of additive manufacturing. The Special Issue consists of 5 original full-length articles on the topic
Additive manufacturing (AM) or, more commonly, 3D printing is one of the fundamental elements of ... more Additive manufacturing (AM) or, more commonly, 3D printing is one of the fundamental
elements of Industry 4.0. and the fourth industrial revolution. It has shown its potential example
in the medical, automotive, aerospace, and spare part sectors. Personal manufacturing, complex
and optimized parts, short series manufacturing and local on-demand manufacturing are some of
the current benefits. Businesses based on AM have experienced double-digit growth in recent years.
Accordingly, we have witnessed considerable efforts in developing processes and materials in terms
of speed, costs, and availability. These open up new applications and business case possibilities all
the time, which were not previously in existence.
Most research has focused on material and AM process development or effort to utilize existing
materials and processes for industrial applications. However, improving the understanding and
simulation of materials and AM process and understanding the effect of different steps in the AM
workflow can increase the performance even more. The best way of benefitting from AM is to
understand all the steps related to that—from the design and simulation to additive manufacturing
and post-processing ending the actual application.
The objective of this Special Issue was to provide a forum for researchers and practitioners to
exchange their latest achievements and identify critical issues and challenges for future investigations
on “Modeling, Simulation and Data Processing for Additive Manufacturing”. The Special Issue
consists of 10 original full-length articles on the topic