This research defined and evaluated mechanical properties of prototypes created using a plaster based three-dimensional printing (3DP) system commercialized by Z Corporation. 3DP is one of the fastest growing forms of rapid prototyping. Till date, there is little or no information available on material properties of infiltrants used in 3DP. This research work evaluated and documented some of the useful information for 3DP users by determining the effect of build position, build orientation and infiltration materials on the strength of prototypes. The study was performed in three different phases to limit the processing variables and to arrive at definite conclusions on relationship between materials properties and process variables. All specimens were built on the Z Corporation Spectrum Z510. In Phase 1, effects of build location on specimen strength was studied. Phase 2 evaluated the influence of build orientation on specimen strength. System Three Clear Coat epoxy was used during both Phase 1 and 2 for infiltration. The same infiltrant was in both of these phases to limit variables. Using results of Phase 1 & 2, the effects of infiltrant material on tensile strength of prototypes was calculated in Phase 3. Seven different infiltrating materials were tested during Phase 3. These materials included 2 cyanoacrylates and 5 epoxies. The tensile strength, flexural strength, and density and porosity of the specimens were determined and correlated. In each phase six specimens were built for each test performed. Two consistent methods of infiltration were utilized to infiltrate cyanoacrylates and epoxies into the as-processed specimens. It was found that the orientation of the specimen has more of an impact on strength than position within the build platform. The layering build process of rapid prototyping creates a variance in strength depending on the build orientation. Specimens infiltrated with epoxy achieved much higher strength than the specimens infiltrated with cyanoacrylate. Cyanoacrylates may be a good choice in making color concept models; however they are not good candidate materials where strength requirement is important. The epoxies with lower viscosities demonstrated higher part strength among the materials tested.

This paper examines the education, events, and experiences of the Wright brothers in order to determine how they developed the necessary skills to engineer the first viable aircraft. Without high school diplomas, and with no advanced formal education, the Wright brothers were able to develop aircraft that far exceeded the capabilities of aircraft designed and built by professional engineers that had worked on the problem of flight for much longer and with substantially larger research budgets. I argue that the Wright brothers’ success resulted from their experiences in the printing and bicycle industries as well as their formal and informal educations at school and in the home. In the printing business it was their experiences designing and building printing presses, printing newspapers, and operating a job printing shop that taught them how to build machinery and work efficiently and methodically. These same skills were perfected as the Wright brothers managed their second business venture: The Wright Cycle Exchange.While working at the bicycle shop the Wrights learned to be proficient machinists as well as expert mechanics and frame builders. This industry provided them with many skills such as brazing and machining that would be directly applicable to aircraft fabrication. In addition to these skills, building bicycle frames and wheels taught them practical material limits and structural design that informed their aircraft design decisions. Moreover, bicycle design influenced their approach to aircraft control and aerodynamic theory that gave them an edge over other aeronautical experimenters in their race to the sky. When these skills were combined with their rigid religious upbringing, the Wright brothers were uniquely prepared to solve the complex problem of practical human flight. It was the combination of their fabrication skills, understanding of material limits, dogged determination, methodical testing procedures, and their unique approach to aircraft control that was informed by their experiences with bicycles that made them the first in flight.

Yes / In this paper, a 2.45 GHz band microwave sensor design is introduced to be utilized for the dielectric constant determination of ethanol-water solutions. The introduced microwave sensor is composed of two symmetrically positioned, directly coupled inter-connected split-ring resonators with a circular ring-shaped detection area in the middle region, into which a small amount of ethanol-water solution is dropped. The fabricated prototype of the microwave sensor has a total component size of 12 mm x 30 mm on Rogers RO4003 substrate. The sensor measurement performance is numerically evaluated and experimentally validated in good agreement. The introduced microwave sensor has the structural design novelty of possessing the main detection region in a form of a circular hollow where a disposable 3D printed fluid cup can be accommodated for multiple uses. The introduced microwave sensor has technical feasibility to be used as an ingredient identification device for the chemical solutions to figure out complex dielectric parameters of ethanol-water specimens with small, low-cost, reusable, easy-to-fabricate features as well as the determination of volume percentage concentration of ethanol content.

Microporous carbonates host a significant portion of the remaining oil-in-place in the giant carbonate reservoirs of the Middle East. Improved understanding of petrophysical and multi-phase flow properties at the pore-scale is essential for the development of better oil recovery processes. These properties strongly depend on the 3D geometry and connectivity of the pore space. In this study, we harnessed the unique capabilities of fluorescence confocal laser scanning microscopy (CLSM) to capture both macroporosity and microporosity, down to 0.1 µm, to provide a more representative 3D representation of pore space compared to traditional methods. The experimental procedure developed was specifically designed to enable highresolution confocal 3D imaging of the pore space of carbonate systems. The protocol aims to render carbonates more "transparent" to CLSM by imaging etched epoxy pore casts of the sample and minimizing CLSM signal scattering. The resulting highquality 3D images of the multi-scale pore space allow more reliable petrophysical interpretation and prediction of transport properties. Additionally, we present a robust pore imaging approach that correlates 2D images produced by scanning electron microscopy (SEM) with the 3D models produced by CLSM that cover a range of scales, from millimeters in 3D to micrometers in 2D. For the first time, multi-color fluorescence confocal imaging was employed to characterize the geometric attributes of a porous medium. We foresee that the protocol developed in this study could be used as a standard protocol for obtaining high-quality 3D images of epoxy pore casts using confocal microscopy, and could contribute to improved characterization of micritic carbonate reservoirs and oil recovery methods. We also demonstrate the advantages of multi-scale and multi-color confocal images in realizing more accurate evaluations of petrophysical properties. Finally, we demonstrate that micro 3D printing (two-photon polymerization) can potentially be used to fabricate micromodels with sufficient resolution to capture the geometric attributes of micritic carbonates and that can replicate the inherent 3D interconnectivity between macro- and micro-pores.

Previous studies have shown that pullulan films are able to stabilize enzymes and other labile molecules from thermal and oxidative degradation. Solutions made with commercially available pullulan are extremely viscous and difficult to process limiting the ability to use low-cost printing systems, such as inkjet printers, to format pullulan-containing. In this work, we show that pullulan can be made printable by decreasing its chain length by acid hydrolysis. The acid hydrolysis reaction was modelled using statistical software; the molecular weight of pullulan decreased with increasing reaction time, temperature and acid concentration. Interactions between time and temperature, and temperature and acid concentration were determined to be significant to the reaction as well. The mechanical properties and oxygen permeability of films made from pullulan with different molecular weights were also measured. The films were found to have similar tensile properties and oxygen permeabilities to each other and to those obtained using native pullulan. Using a thermally unstable enzyme (acetylcholinesterase) and an easily oxidizable small molecule (indoxyl acetate) as test materials, it was found that these films have the same ability to stabilize the enzyme and to serve as an oxygen barrier, as the films made with native pullulan. It was also found that pullulan is inkjet printable as long as the molecular weight is 56 kDa. Poor jetting and clogging of the printhead was observed when pullulan with a molecular weight higher than this threshold was used. Microarray printing was also demonstrated by a printing acetylcholinesterase/pullulan in nano-sized volumes using a Dimatix inkjet printer and showing activity of the enzyme after printing and storage at ambient conditions. Proof of concept of microarray printing opens up the potential for future applications of pullulan in other high throughput applications. / Thesis / Master of Applied Science (MASc)

Research interest in Additive Manufacturing (AM) as an enabling technology for customizable parts is rapidly expanding. While much AM research focus is on high performance feedstocks and process optimization to obtain parts with improved mechanical properties, interest in the environmental applications of AM has recently increased. The lower cost and greater accessibility AM is leading to novel environmental research solutions in wastewater treatment and toxicity reduction by capitalizing on the increased affordability and accessibility of 3D printing (3DP) technologies for customizable, high surface area structures. The novelty and focus of this dissertation is exploration of Material Extrusion (MatEx) based Fused Filament Fabrication (FFF) of filled polymer composites as a disruptive technology enabler for deployable and retrievable structures in environmental media for adsorption, destruction and toxicity reduction of harmful chemicals. This dissertation addresses research questions that generally answer, "why AM for environmental applications?". The inherent layer-by-layer design provides larger surface area structures for interaction with contaminated media. Polylactic acid (PLA) was selected due to its green sources and biocompatibility relative to synthetic polymers and its wide processing window allowing shear thinning and "printability" despite the elevated viscosity and modulus of highly filled composites. The filler selected for contaminant adsorption was microporous zeolite, which has affinity for ammonia, radionuclides and Per- and Polyfluorinated Substances (PFAS). The filler selected for contaminant destruction was photocatalytic TiO2 nanoparticles which can degrade organic chemicals, harmful algal bloom toxins and PFAS. A preliminary research hurdle was overcome by demonstrating that immobilization of zeolite and TiO2 in a PLA binder matrix did not prevent adsorption or free radical release, respectively. The first major research objective involved investigation of high surface area printed PLA-zeolite geometries with different zeolite loadings and found that while ammonia was reduced, there were diminishing returns with increased loading in terms of mass standardized adsorptive performance due to insufficiently exposed zeolite. The research solution leveraged AM print process parameters to increase the macroporosity of the printed composite structure to create voids and channels allowing water infiltration and chemical adsorption to zeolite. Faster printing of larger roadways generated macrostructural voids that were maintained by extrusion at lower temperature for rapid solidification. The second research objective involved compounding different loadings and dispersion states of TiO2 in PLA to demonstrate immobilization of TiO2 closer to UV-light penetration water improves photocatalysis. Higher 32% w/w TiO2 loadings were heavily agglomerated and more difficult to print process due to high viscosity, rapid liquid-solid transition (G'>G") and particle network recovery during printer retractions, leading to nozzle clogging. Lower 20% w/w loading was more conducive to larger production printing due to lower viscosity, longer viscosity recovery times for retractions and thus generally a wider processing window. While altering twin screw processing parameters reduced TiO2 agglomerates in filaments, leading to increases in crystallinity (due to seeding effects and chain scission) and lower viscosity recovery, photocatalytic performance was not significantly improved. Evidence presented showed that larger particle agglomerates were more toward the inside of printed surfaces and thus less available to UV-light irradiation. This location of larger particles is supported by previous theoretical and empirical investigations showing larger particles migrate at a faster velocity away from the outer walls of confined extrudates within non-Newtonian flow fields due to normal forces, leaving more smaller particles toward outer surfaces. This research provided novel contributions to the environmental and AM research communities and pioneered a convergence of these fields into an interdisciplinary community of practice focused on better characterization and processing in environmental applications to improve structure-environmental property relationships. Future research should build on these findings to enhance performance through multi-functional materials that adsorb and destroy contaminants. The reactive surface area should be further increased through by high surface area designs and print parameter optimized porous structures providing a continuum of meso- to microporosity as confirmed by chemical flux and mass transfer studies for additional AM technologies (e.g., Direct Ink Write). / Doctor of Philosophy / Engineers and hobbies alike have great interest in Additive Manufacturing (AM), or 3D Printing, to customize parts and new designs. More recently, environmental scientists and engineers have turned to 3D printing to solve environmental problems due to the lower cost and user-friendliness of desktop machines. This research dissertation focuses on how 3D printing can allow for iterative improvements in customizable, high surface area structures to reduce chemical concentrations in water by either adsorbing or destroying the chemicals. Water is clearly a critical resource for ecosystems, recreation and drinking supplies as national security, human and ecosystem health are tied to clean water. This research addresses why 3D printing is interesting and effective for environmental solutions. Briefly the layer-by-layer design provides larger surface area structures for interaction with contaminated media. The common 3D printer feedstock Polylactic Acid (PLA) was selected since it is non-toxic and can be relatively easy to print even if modified by adding rigid filler particles for research. Micron-scale (zeolite) and nano-scale (Titanium Dioxide) particles were mixed with the polymer to make printable filaments to adsorb and destroy contaminants, respectively. This research demonstrated the proof-of-concept by removing ammonia, methylene blue dye and a harmful algal toxin from water. The materials produced are also applicable to both conventional organic pollutants and emerging contaminants of concern in the popular news such as Per- and Polyfluorinated Substances (PFAS), which were used as flame retardants and non-stick surfaces. This research ties the material properties of the experimental micro- and nano-composite filaments to how the materials extrude and solidify during 3D printing and how well the resulting printed structures work for reducing contaminant levels in water. Altering the parameters and conditions at which these materials are processed and 3D printed can significantly change their structure, density, porosity and distribution of particles and in turn increase effectiveness. The results provide new contributions to both the environmental and AM research communities and pioneers interdisciplinary collaborative ideas for these different subject matter experts to work together to better understand how handling and processing of these materials can improve their performance in environmental applications. New work should leverage the ideas and principles presented here to further improve performance, ease of production and scale-up of multifunctional material structures for multiple classes of chemicals that are of concern in surface and drinking water.

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Bio-interface topography strongly affects the nature and efficiency of interactions with living cells and biological molecules, making hydrogels decorated with micro and nanostructures an attractive choice for a wide range of biomedical applications. Despite the distinct advantages of protein hydrogels, literature in the field has disproportionately focused on synthetic polymers to the point that most methods are inherently incompatible with proteins and heat-sensitive molecules. We report the development of multiple biomolecule-friendly technologies to construct microstructured protein and bacteriophage (bacterial virus) hydrogels. Firstly, ordered and sphericity-controllable microbumps were obtained on the surface of protein hydrogels using polystyrene microporous templates. Addition of protein nanogels resulted in the hierarchical nano-on-micro morphology on the microbumps, exhibiting bacterial repellency 100 times stronger than a flat hydrogel surface. The developed microstructures are therefore especially suitable for antifouling applications. The microstructures created on protein hydrogels paved the way for applying honeycomb template on proteinous bacterial viruses. We developed a high-throughput method to manufacture isolated, homogenous, pure and hybrid phage microgels. The crosslinked phages in each phage-exclusive microgel self-organized and exhibited a highly-aligned nanofibrous texture. Sprays of hybrid microgels loaded with potent virulent phage effectively reduced heavy loads of multidrug resistant Escherichia coli O157:H7 on food products by 6 logs. / Thesis / Doctor of Philosophy (PhD) / Bacteriophages (bacterial viruses), also known as phages, are natural bacteria predators. These viruses act as direct missiles, each phage targeting limited groups of bacteria. In addition, phages are an endless resource for self-propagating nanoparticles that can be used as building blocks for new material. I developed a platform for manufacturing a large quantity of microscale beads made of millions of phages. These micro-beads can be sprayed on fresh produce and meat to remove bacterial contamination (with the added benefit of not affecting taste or smell). I also printed phages on substrates, like an ink. The printed phage ink evolved into a patented technology for designing phage coatings on surfaces with very high surface area, like the small structures on our fingers. This phage coating was successfully used to test the existence of bacteria in liquids.

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No description available.