Nscrypt (United States)

Known as the "golden hour," survival of most critically injured patients is highly dependent on providing the required treatment within the first hour of injury. Recent technological advances in additive manufacturing (also known as three-dimensional [3D] printing) allow for austere deployment and point-of-care rapid fabrication of a variety of medical supplies, including human tissues and bioactive bandages, in prolonged field care scenarios. In this pilot project, our aim was to investigate the ability to 3D print a range of potential biomedical supplies and solutions in an austere field environment. We specifically designed and fabricated novel surgical tools, bioactive bandages, objects (screw and anatomic models), and human meniscal tissue in an austere African desert environment. A total of seven packages were sent using a commercial carrier directly to the end destination. A multi-tool ruggedized 3D printer was used as the manufacturing platform for all objects fabricated downrange. Human mesenchymal stem cells were shipped for 3D bioprinting of human menisci and bioactive bandages. Design and fabrication for all 3D-printed products utilized computer-aided design (CAD) tools. Initial shipment from a single U.S. site to the sub-Saharan Africa location was relatively prompt, taking an average of 4.7 days to deliver three test packages. However, the actual delivery of the seven packages from Orlando, FL, to the same sub-Saharan Africa site took an average of 16 days (range 7-23 days). The ruggedized printer successfully fabricated relevant medical supplies using biocompatible filament, bioink hydrogels, and stem cell-loaded bioinks. This prototype did not, however, have the capacity to provide a sterile environment. A multi-material complete bandage was 3D printed using polyamide polyolefin and cellulose, live cells, neomycin salve, and adhesive. The bandage, wound covering backing, and adhesive backing print took under 2 min to 3D print. Surgical instrument CAD files were based on commercially available medical-grade stainless-steel instruments. The screw CAD file was downloaded from the NIH 3D Print Exchange website. The prints of the two surgical tools and screw using thermoplastic material were successful. Menisci, relatively complex forms of the cartilage, were 3D bioprinted with a gel that held their form well after printing and were then solidified slightly using a cross-linking solution. After 2 min of solidification, it was possible to remove and handle the menisci. The current and future challenges of prolonged field care need to be addressed with new techniques, training, and technology. Ruggedized, deployable 3D printers allow for the direct fabrication of medical tools, supplies, and biological solutions for austere use. Delivery of packages can vary, and attention to routes and location is key, especially for transit of time-sensitive perishable supplies such as live cells. The significance of this study provides the real possibility to 3D print "just-in-time" medical solutions tailored to the need of an individual service member in any environment. This is a potentially exciting opportunity to bring critical products to the war front.

Abstract This article is a detailed account of the advantages, disadvantages, and applications of microdispensing processes used in electronics manufacturing industries. The discussion covers various approaches to control material flow, namely time pressure, auger, positive displacement, and progressive cavity pump dispensing. The concept of valving to control starting and stopping is also discussed. The applications include printing solders in microelectronic packaging, printing to pads, printing conductive patterns for antennas, printing active circuits, printing on flexible surfaces, and structural printing.

ABSTRACT Adhesive dispensing has been widely used in the electronic industry for decades. Recently the demand for smaller size & volume coupled with precision and flexibility of adhesive placement is increasing due to the advancement of miniaturized electronic components and devices. New adhesives are needed to meet the desired bonding requirement given reduced volume. Sometimes high viscosity adhesives are used since they have the advantage of holding the feature shape after dispensing which allows smaller feature sizes without sacrificing the volume needed for the bonding. Dispensing adhesives is not challenging, but doing this with sub nanoliter or picoliter level with good precision is not trivial. This paper presents a robust micro-dispensing solution for adhesives and polymers with 100 picoliter volume control. The unique valve and nozzle tip design provide exceptional control of medium and high viscosity materials and including materials with particle loading. A standard industrial adhesive for flip chip applications was used for this study. The short & long term repeatability of these printed features as well as the robustness of the wetted parts were demonstrated.

ABSTRACT Embedded Passive Technology is a viable technology that has been reliably used in the defense and aerospace industry for over 20 years. Embedded Passive (Resistors and Capacitors) Technology have a great potential for high frequency and high density applications. It also provides better signal performance, reduced parasitic and cross talk. This paper summarizes the selection of resistor embedded materials, evaluations of resistive material (Phase 1) and duplication of a complex digital design (Phase 2). Phase 1 – Ticer’s TCR® resistive materials (Foil 25Ω/sq NiCr and 1kΩ/sq CrSiO) and Ohmega resistive-Ply materials (Ohmega-Ply 25Ω/sq and 250Ω/sq NiP) were chosen for evaluation. Phase 2 – Due to the high level of complexity and advance materials dielectric, the Digital Imaging Processor unit was chosen as an evaluation vehicle. Process Evaluation for embedded was used to determine present process gaps for laser trimming, fabrication material, raw board test and defining specifications for DFM and layout design.

Implementing electronics systems that are conformal with curved and complex surfaces is difficult if not impossible with traditional fabrication techniques, which require stiff, two dimensional printed circuit boards (PCB). Flexible copper based fabrication is currently available commercially providing conformance, but not simultaneously stiffness. Consequently, these systems are susceptible to reliability problems if bent or stretched repeatedly. The integration of Additive Manufacturing (AM) combined with Direct Print (DP) micro-dispensing can provide shapes of arbitrary and complex form which incorporate 1) miniature cavities for insetting electronic components and 2) conductive traces for electrical interconnect between components. The fabrication freedom introduced by AM techniques such as stereolithography (SL), ultrasonic consolidation (UC), and fused deposition modeling (FDM) have only recently been explored in the context of electronics integration. Advanced dispensing processes have been integrated into these systems allowing for the introduction of conductive inks to serve as electrical interconnect within intricately-detailed dielectric structures. This paper describes a process that provides a novel approach for the fabrication of stiff conformal structures with integrated electronics and describes several prototype demonstrations: a body conformal helmet insert for detection of Traumatic Brain Injury (TBI), a 3D magnetic flux sensor with LED indicators for magnitude and direction and a floating sensor capable of detecting impurities in water while maintaining orientation through density gradients.