3D printing has revolutionised traditional manufacturing methods, opening up and distributing design and production of low cost, custom objects to virtually anyone. Tailoring of print material and part geometry allows for the benefits of this technology to reach multiple engineering and scientific fields, given appropriate design. A multidisciplinary approach concerning development of new print materials and methods was undertaken with the aim of further expansion and application of 3D printing towards electrochemical applications. Specific requirements of materials used in this domain, such as conductivity and chemical stability, led to development of functional printable carbon composites, compatible with consumer grade 3D printers. This allows facile production of cheap, reusable, disposable, electrodes for analytical applications, demonstrating heavy metal detection in aqueous media and allowing further tailoring to specific applications to be easily implemented. A new method for printing of cellulose solutions was developed, with post processing of printed parts resulting in biocompatible, porous, conductive structures. When used as electrodes in microbial fuel cells, improved power and current output over traditionally used carbon cloth electrodes was achieved. Other developments resulting from this work applicable to other fields include a novel trajectory generation method based on exponential functions which can be applied to practically any robotic system, as well as improvements to the production process of metal alloy filaments for 3D printing of metallic components.

Current debates on design and manufacturing support the claim that the ‘Third Industrial Revolution’ has already started due to Additive Manufacturing (AM) and 3D Printing. The process of solidifying liquid or powder using a binding agent or a melting laser can save time and transportation costs associated with importing primary material if locally sourced material is available. This research investigates a framework approach, titled SAFE, for discussing the functionality, economic viability, production feasibility, and aesthetic and cultural value lent by 3D printing on an architectural scale through a construction known as a Mashrabiya. This traditional window screen has distinguished aesthetic, cultural yet functional constraints, and there is a manufacturing gap in the market that makes it a viable product option to be 3D printed. The practical element and design process related to reviving this screen are examined, from complex geometry development to cost and fabrication estimations. 3D printing technologies potentially offer solutions to solve issues in construction and assembly times, reduce labour costs, and address the loss of hand craft making skills in a variety of cultures, typically Middle Eastern ones; this was a factor in the abandonment of old Mashrabiya in houses typified with Bahrain as a case. Presently, there is a growing wealth of literature that highlights not only the strength of Mashrabiya as a design concept but also as a possible 3D printed product. Interviews with a total of 42 local Bahraini manufacturers, academics and architects as well as 4 case studies and 2 surveys and 11 focus groups are hybrid mixed methods used to define a new 3D printed Mashrabiya (3DPM) prototype. The future of the 3D Mashrabiya prototype is further supported by economic forecasts, market research, and interviews with global manufacturers and 3D printing designers’ insights into the subject in an accretive design process. The research contributes to an understanding of the implications of technologies that enable mass customisation in the field of 3D-printed architecture in general and in the Bahraini market in particular. The process for developing a prototype screen and in determining its current economic value will prove significant in predicting the future benefits and obstacles of 3D-printed large scale architectural products in the coming five years as advised by industry experts. The main outcomes relate to establishing boundaries determining the validity of using 3D printing and a SAFE framework to produce a parametric Mashrabiya and other similar heritage architectural archetypes. This can be used to enhance the globalism of the design of Middle Eastern dwellings and to revive social identity and cultural traditions through innovative and reasonable yet superior design solutions using a hybrid architectural design language.

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The goal of the thesis was to design a piston manufactured by conventional method and subsequently adjusted one for additive manufacturing. Beside the designs, thermo-structural model was created for both pistons, considering maximal loading of the engine. Analysis evaluation showed the possibility of further application of the new technology in comparison to current one, within automotive industry.

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One of the major technical challenges with creating 3D artificial tissue constructs is the lack of simple and effective methods to integrate vascular networks within them. Without these vascular-like networks, the cells embedded within the constructs quickly become necrotic. This thesis details the use of a commercially available, low-cost, 3D printer modified with a microfluidic printhead in order to generate instantly perfusable vascular-like networks integrated within gel scaffolds seeded with cells. The printhead featured a coaxial nozzle that allowed the fabrication of hollow, gel tubes (500µm–2mm) that can be easily patterned to create single or multi-layered constructs. Media perfusion of the channels caused a significant increase in cell viability. This microfluidic nozzle design was further modified to allow for multi-axial extrusion in order to 3D print and pattern bi- and tri-layered hollow channel structures. Most available methodologies lack the ability to create multi-layered concentric conduits inside natural extracellular matrices, which would more accurately replicate the hierarchal architecture of biological blood vessels. The nozzle used in this work allowed, for the first time, for these hierarchal structures to be embedded within layers of gels in a fast, simple and low cost manner. This scalable design allowed for versatility in material incorporation, thereby creating heterogeneous structures that contained distinct concentric layers of different cell types and biomaterials. This thesis also demonstrates the use of non-extrusion based 3D biofabrication involving planar processing by means of hydrogel adhesion. There remains a lack of effective adhesives capable of composite layer fusion without affecting the integrity of patterned features. Here, silicon carbide was found for the first time to be an effective and cytocompatible adhesive to achieve strong bonding (0.39±0.03kPa) between hybrid hydrogel films. Multi-layered, heterogeneous constructs with embedded high-resolution microchannels (150µm-1mm) were fabricated in this way. With the new 3D fabrication technology developed in this thesis, gel constructs with embedded arrays of hollow channels can be created and used as potential substitutes for blood vessel networks as well as in applications such as drug discovery models and biological studies. / Thesis / Doctor of Philosophy (PhD) / Additive manufacturing (AM) involves any three-dimensional (3D) fabrication technologies that is used to produce a solid model of a predetermined design. AM techniques have recently been used in tissue engineering applications for fabrication of 3D artificial tissues that resemble architectures and material properties similar to that of the native tissue. Utilizing AM for this purpose presents the advantage of increased control in feature patterning, which leads to the realization of more complex geometries. However, there still remains a lack of simple and effective methods to integrate vascular networks within these 3D artificially engineered scaffolds and tissue constructs. Without these vascular-like networks, the cells embedded within the constructs would quickly die due to a lack of nutrient delivery and waste transport. This remains one of the biggest challenges in true 3D tissue engineering. This thesis presents a number of fast, effective and low-cost AM biofabrication techniques to address this challenge.

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Stab resistant body armour had been used throughout history, with examples ranging from animal hide construction to the moulded Polycarbonate units typically used by United Kingdom (UK) Police Officers. Such protective articles have historically, and continue to present a number of issues which have shown to impair the operational performance of its wearer including but not exclusive to poor thermal regulation, large masses, and reduced manoeuvrability. A number of developments have been made in an attempt to minimise the effects of such issues. One potential solution yet to be fully explored is the utilisation of Additive Manufacturing (AM) technologies. In recent years the use of such manufacturing technologies, particularly Laser Sintering, has successfully demonstrated their suitability for a range of high performance applications ranging from Formula 1® to aerospace. Due to the fundamental additive nature of AM build processes, the utilisation of such technologies have facilitated the realisation of design concepts that are typically too expensive, difficult or impossible to create using traditional manufacturing processes. In order for AM technologies to be used for the generation of stab resistant body armour a number of historical issues and performance characteristics fundamental to ensure stab resistance is achieved must be satisfied. This body of research firstly evaluated the stab resistive performance of two of the most common materials suitable for Laser Sintering as highlighted by an initial review of AM technologies. Once an appropriate material had been highlighted it was used as the basis for further experimental testing. Such tests focussed on minimising the material thickness required to maintain an appropriate level of stab resistance within United Kingdom Home Office Scientific Development Branch (HOSDB) KR1-E1 requirement of 24 Joules of stab impact energy. Test results demonstrated that specimens manufactured from Duraform EX® required a minimum single layer thickness of 11.00 mm, and a dual layer total thickness of 9.00 mm to provide an appropriate level of stab protection within the HOSDB KR1-E1 standard. Coupled with the results generated from an investigation identifying the overlapping/imbricated assembly angle required to maintain an appropriate level of coverage across a scale structure, the stab resistant characteristics initially identified were used for the development of an imbricated scale-like assembly. Additional design features were also investigated to further minimise the total thickness of the final element design and corresponding assembled imbricated structure such features included angling strike surfaces and integrating a dual layered structure within individual elements. When the finalised imbricated assemblies were stab tested, they successfully demonstrated levels of stab resistance to the UK HOSDB KR1-E1 impact energy of 24 Joules.

The first objective of this thesis was compiling research about currently produced pistons for internal combustion engines and about additive manufacturing and based on the acquired information deciding which type of piston makes the most of the advantages. Following this research, the next step was creating a design adjustment of a piston, which was previously designed with the conventional methods of manufacturing in mind, in a way that would make the best use of the different possibilities of additive manufacturing. There was also an optimisation carried out, which depicted the densities of material elements in the piston, showing where the material was less important. There were three variants of the additive manufactured piston created, ranging from a relatively conservative design, which could be theoretically produced by conventional methods with a more substantial subtraction of material added, to a design which could only be produced via additive manufacturing. A thermo-structural analysis at maximum engine load was carried out for all these piston models. Based on these data, a conclusion was made, whether the use of additive manufacturing was justified over the use of the conventional subtractive methods.

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