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The primary focus of this thesis is the study of visual development for worldbuilding, starting with creative writing and documentation and translating the written content into visual concepts in both 2D and 3D. This project includes an original narrative, setting, and characters and explores aspects of the visual development pipeline. The content below contains work in visual research, 2D character design, 3D character sculpting, 3D printing and assembly, hard-surface modeling, matte-painting, illustration, compositing, and heavy creative writing.

In this thesis, the successful fabrication of 3D-printed microfluidic devices will be discussed. Fabrication is performed with a low-cost commercially available stereolithographic 3D printer utilizing a custom PEGDA resin formulation tailored for low non-specific protein adsorption based on my colleagues' work [Rogers et al., Anal. Chem. 83, 6418 (2011)]. Horizontal microfluidic channels with designed rectangular cross sectional dimensions as small as 300 um wide and 150 um tall are printed with 100% yield, as are cylindrical vertical microfluidic channels with 300 um designed (334 um actual) diameters. Moreover, two different resins developed by our group are utilized in the process of 3D-printing which is the novel aspect about this thesis since other groups have not done research on this aspect of 3D-printing.

Biomarkers are measurable indicators of health status or disease state that can be used for diagnosis and may help guide patient treatment strategies. Enzyme-linked immunosorbent assays (ELISA) and other many clinical techniques currently used for measuring biomarker proteins lack sensitivity, demand high analysis cost, are often not well-suited for measuring multiple biomarkers in a single sample, and require long analysis times. Here, we demonstrate simple, low-cost 3D-printed flow-through devices with integrated electrodes modified with gold nanoparticles (AuNPs) for electrochemical immunoassays of S100B, a biomarker protein related to conditions like skin cancer and brain injuries. Flow-through devices are fabricated from photocurable-resin using a desktop digital light processing (DLP) projector-based 3D printer to produce 500-800 µm square cross-sectional fluidic channels. Threaded ports at the ends and center of the channel are included in the device design for connecting commercially available fittings for fluid delivery and integrating low-cost graphite electrodes for electrochemical biosensing.

The purpose of this study is to examine the position and use of an upper extremity prosthetic simulator on non-amputees. To see how a 3D printed prosthetic simulator can be optimized to serve the user correctly and accurately. In addition, this study examines the improvement of the Hosmer 5X Prosthetic Hook with the addition of newly designed trusses on to the prosthetic, as well as utilizing a new manufacturing method known as 3D printing. These topics are important because there is no standardized prosthetic simulator for schools and research facilities to use. Off the shelf prosthetic simulator cost upwards of $2000, often too expensive for early stage research. By optimizing the Hosmer 5X Prosthetic Hook with 3D printing, this new opportunity could allow amputees, from a range of income classes, to have access to a wide variety of prosthetics that are strong enough to support everyday living activities. A low-cost prosthetic that is easily distributable and accessible can give people a chance to regain their independence by giving them different options of efficient prosthetic devices, without having to spend so much. The devices in this project were design and analyzed on SOLIDWORKS, 3D scanned on the Artec Space Spider, and surfaced on Geomagic Wrap. Key results include developing a low-cost, robust prosthetic simulator capable of operating a Hosmer 5X Prosthetic hook, as well as developing a lighter version of the Hosmer 5X Prosthetic Hook that is more cost efficient and easily obtainable to the population around the world.

Tissue engineering is a dichotomy of scaffold-based and scaffold-free cultures. Scaffold-based cultures form highly organotypic structures but with low uniformity and throughput. Conversely, scaffold-free cultures create consistently sized and shaped cell aggregates with limited spheroid-like structure and function, thus restricting their use for accurate disease modeling. We hypothesized that combining aspects of each culturing format, we would produce highly organotypic structures of consistent size and shape for use in pulmonary modeling. First, to improve on culture consistency and output, we created a novel easily scalable, minimalistic design for a micropatterned hydrogel dish that increases reliability and efficiency in 3D cell culture. This dish design features three times more efficient media change relative to commercially available plates. Moreover, we discovered that formation of consistently sized and shaped cell aggregates depended on hydrogel stiffness. Second, we developed a biocompatible 3D printing resin using poly(ethylene glycol) diacrylate (PEGDA) monomer with avobenzone as the UV absorber instead of 2-nitrophenyl phenyl sulfide (NPS). The polymerized resin could be surface activated to promote cell adhesion. This resin could be used in high-resolution printing of miniature devices for microfluidic and nanofluidic cell culture and cell assays. Third, we show a unique improvement on current methods to produce organotypic aggregates via suspension culture. By using soluble non-gelling concentration of basement membrane (BM), we created an organotypic lung model from three stable cells representing epithelial, vascular, and fibroblast cell populations within 14 days of culture. We observed that soluble BM promotes emergence of lumina comparable to mammalian lung airspaces. Using hypoxia induction techniques, we provide evidence for formation of branching, perfusable vasculature in pulmonary aggregates supplemented with soluble BM. Aside from these structural traits, we observed increased proliferation, survival, and 3D growth of aggregates. These results were supported by proteomic studies. As proof of concept, we applied this method in modeling of lung fibrosis using bleomycin induction followed by testing one investigational antifibrotic drug. Our results demonstrate a novel 3D culture method that creates organotypic models from stable cell lines. We anticipate this technology to pioneer creation of novel suspension-based organoids fostering consistent, expedited 3D culture. In summary, these three technologies highlighted in this dissertation improved on the 3D culture status quo. We view these technologies to have the potential to expedite creation of patient-derived organoids for personalized drug screening using lung-on-a-chip assays.

[pt] O presente trabalho propõe um novo tipo de ligação entre perfis pultrudados que não exija furação do material, seja leve e fabricado por manufatura aditiva. Para isso, fez-se uma revisão do estado da arte no âmbito das ligações entre perfis de compósitos, abordando ligações parafusadas simples, cujos parafusos estão sujeitos apenas ao corte, bem como as ligações semirrígidas, que são menos contempladas pela literatura atual. Além disso, tratou-se do uso de otimização topológica em componentes mecânicos voltados à impressão 3D. Posteriormente, define-se a geometria básica do componente proposto e o respectivo modelo numérico adotado no processo de otimização topológica, expondo todas as condições de contorno, carregamento e otimização. A fim de verificar experimentalmente o comportamento do componente apresentado, ensaios momento-rotação foram realizados em três grupos, sendo um composto por exemplares com a geometria original básica e os demais por componentes otimizados (com e sem reforço). Por fim, foi observado que o caminho de fibras estabelecido foi coerente com as solicitações às quais o componente está submetido, haja vista a maior eficiência manifestada pelo aumento de resistência e rigidez por unidade de massa. A mesma constatação se aplica ao processo de otimização e ajuste. No mais, a utilização do reforço com fibras implicou numa maior repetibilidade na resposta mecânica da ligação. / [en] The current work proposes a new type of joint between pultruded profiles that does not require drilling, is lightweight and build by additive manufacturing. To accomplish that, a state of art review on pultruded profiles joints was carried, addressing simple bolted joints which have their bolts only subjected to shear, as well as semi-rigid joints. Besides, the use of topology optimization on 3D-printed mechanical components is also addressed. Posteriorly, the basic geometry of the proposed component is defined and its respective numeric model used within the topology optimization, presenting their boundary, load and optimization conditions. In order to experimentally verify the behaviour of the component, moment-rotation tests were carried in three groups, namely, the original geometry group, the simple optimized group and the reinforced optimized group. In the end, it was observed that the defined fibre path is consistent with the stresses acting within the component, regarding the greatest efficiency shown in terms of strength and stiffness per unit mass for the reinforced specimens. The same applies to the optimization and adjusting processes. Furthermore, the use of fibre reinforcement led to a greater repeatability of mechanical response.

The automotive industry faces the challenge to manufacture vehicles with reduced material usage and climate impact. To achieve this the industry has begun using other materials such as carbon fibre composite than materials such as steel and aluminium which are normally used for the manufacturing of automobile parts. Because its anisotropic structure gives the manufacturer increased opportunity to selectively use the material for the part’s stability and ability to withstand loads However Carbon fiber has drawbacks, the material is time-consuming to work with and expensive, because such automobile parts are either made by hand or with precisio nmolding equipment that requires experienced and educated personnel to produce parts with satisfactory quality. A car component whose weight reduction is crucial is the car rim. The car rims and tire’s weight determines the wheel shaft’s torque needed for steering which makes it an important component of the car. This work examines a manufacturing technology with the potential to reduce material use and the climate impact of car rims manufacturing. The manufacturing technology involves a robotic system that weaves carbon fiber threads on a winding frame that sits on a rotary table. The work’s purpose is to derive a theoretical model which describes the following characteristics: Production time, material usage, how the carrim and winding frame are to be adapted to one another to ensure the car rim can withstand loads to which it can be expected to be subjected.The objective is to generate data which describes these characteristics. To derive a theoretical model and generate data which describes the manufacturingstechnology’s characteristics, the work was split into two parts; In the first part, a theoretical formula was derived to relate material usage with the used length of a carbon fibre thread. Simulations are made to relate material usage and production time with theory for a PID-regulator.In determining the weaving pattern, material technology’s theory for anisotropy is used. The second part involves using theory from solid mechanics to derive theoretical equations which describes how the winding frame and car rim’s dimensioning are to be adapted to one another, with regards to the car rim’s critical parameters. Which in this work is the car rim’s stiffness and carbon fibre’s yield strength. To test the mechanical performance of the car rim, Finite-element-method(FEM) simulations are made and the validation of the simulation is done with the derived theoretical equations. In simplifying the work, winding frame, weaving pattern, and car rim are visualized using Computer-aided-design(CAD) tools. The conclusion from the results is that while the theoretical model showcases the manufacturing technology’s potential but further work is needed to improve it and adapt it to car rim’s industrial standards.

Aortic stenosis is a serious cardiovascular disease that requires urgent attention and surgical intervention. If not treated, aortic stenosis can result in heart attack or cardiac arrest. Transcatheter Aortic Valve Replacement is a surgical technique that is used to treat aortic stenosis. Like all heart surgery, the procedure is difficult to perform and may lead to life-threatening complications. It is therefore important for a surgeon to be able to plan and rehearse the surgery before the operation to minimise risk to the patient. A detailed study was carried out to develop a 3D-printed, improved surgical tool for patient-specific planning and rehearsal of a Transcatheter Aortic Valve Replacement procedure. With this new tool, a cardiologist will be able better to understand a specific patient’s heart geometry and practice the procedure in advance. Computer tomography images were processed using image segmentation software to identify the anatomy of a specific patient’s heart and the surrounding blood vessels. Using materials design concepts, a polymer composite was developed that is able to mimic the mechanical properties of aortic tissue. State-of-art multi-material 3D printing technology was then used to produce a replica aorta with a geometry that matched that of the patient. An artificial aortic valve, identical to the type used in the Transcatheter Aortic valve replacement procedure, was then fitted to the replica aorta and was shown, using a standard test, to be a good fit with no obvious leaks. / Aortastenos är en hjärtsjukdom som får mycket uppmärksamhet och kräver kirurgi på grund av dess katastrofala komplikationer. Den allvarligaste komplikationen av aortastenos är hjärtinfarkt och resulterande hjärtstopp. Transcatheter Aortic Valve Replacement är en kardiovaskulär intervention som erbjuds för patienter med aortastenos. Denna typ av hjärtkirurgi är komplex och kan orsaka livshotande situationer för patienten om något går snett under operationen. Det är därför viktigt för kirurgen att kunna planera ingreppet innan han eller hon utför själva operationen för att minimera fara för patienten. Denna detaljerade studie ämnar utveckla och förbättra det kirurgiska verktyget för preoperativ planering av Transcatheter Aortic Valve Replacement genom 3D- tryckning. Forskningsarbetet kommer att ge kardiologer ett nytt sätt att förstå patientens hjärta i detalj och ett ökat förtroende för att träna på ingreppet på förhand. Datortomografibilder behandlades med hjälp av en bildsegmentationsprogramvara för att kunna skapa en anatomiskt korrekt kopia av patientens hjärta och tillhörande kärl. Genom att applicera material-vetenskapslära kan ett nytt kompositmaterial utvecklas med exakt samma mekaniska egenskaper som naturlig aortavävnad. Den mest moderna 3D-trycktekniken användes sedan för att producera en patientspecifik aorta. En artificiell aortaklaff placerades i den nyproducerade aortamodellen och tester visade en perfekt matchning utan läckage.