Santosh Kumar Parupelli

This study presents the design, fabrication, and evaluation of a 3D printed GRID collimator for spatially fractionated radiation therapy (SFRT). In this research, the mechanical and radiological performance of the 3D printed GRID collimators fabricated using polylactic acid (PLA), acrylonitrile styrene acrylate (ASA), and acrylonitrile butadiene styrene (ABS) materials were investigated. Mechanical stability of the GRID collimators was evaluated to assess load-bearing capacity and deformation behavior. Noticeable differences in the maximum load and deformation were observed for ABS, PLA, and ASA GRIDs. ABS material exhibited enhanced mechanical strength and superior resistance to deformation compared to PLA and ASA. The findings of the mechanical analysis illustrate the ABS 9.0 cm thickness GRID with 100% infill density exhibited the highest load-bearing capability, observed to be 2268 N at failure. Further, the percent depth dose and the peak-to-valley-dose ratio (PVDR) metrics of the GRID collimator were investigated using radiation to validate dose modulation capabilities. The dosimetry tests revealed that a higher PVDR (6.8) was achieved by the 9.0 cm ABS tungsten-filled GRID collimator with 100% infill density at 6 MV. Thus, this device with higher PVDR is preferred for the enhanced tumor control during the SFRT treatment. Our results demonstrate that 3D printed GRID collimators provide customized design, mechanically stable devices, and preferred dosimetry modulation.

Lithium-ion batteries (LIBs) have become the prominent energy storage technology because of their high specific energy, longer lifespan, and excellent efficiency. Traditional lithium extraction processes are energy intensive and time-consuming. Direct lithium extraction (DLE) methods provide a more sustainable and efficient alternative. This review offers a comprehensive overview of lithium-ion battery resources and direct lithium extraction methods. The detailed discussion of the DLE methods, which include adsorption, ion exchange, solvent extraction, membranes separation, and electro-chemical systems is presented. A comprehensive analysis of the recent technological advances of the direct lithium extraction processes in terms of technology readiness levels, and commercial potential is reported. The advantages and the technical challenges of the DLE methods are also reported. Finally, the review outlines the artificial intelligence outlook of the DLE processes. The review aims to provide deeper insights into the limitations and the opportunities of DLE methods towards crucial future research efforts for lithium-ion batteries advancements.

This review explores the transformative role of three-dimensional (3D) printing in radiation therapy for cancer treatment, emphasizing its potential to deliver patient-specific, cost-effective, and sustainable medical devices. The integration of 3D printing enables rapid fabrication of customized boluses, compensators, immobilization devices, and GRID collimators tailored to individual anatomical and clinical requirements. Comparative analysis reveals that additive manufacturing surpasses conventional machining in design flexibility, lead time reduction, and material efficiency, while offering significant cost savings and recyclability benefits. Case studies demonstrate that 3D-printed GRID collimators achieve comparable dosimetric performance to traditional devices, with peak-to-valley dose ratios optimized for spatially fractionated radiation therapy. Furthermore, emerging applications of artificial intelligence (AI) in conjunction with 3D printing promise automated treatment planning, generative device design, and real-time quality assurance, and are paving the way for adaptive and intelligent radiotherapy solutions. Regulatory considerations, including FDA guidelines for additive manufacturing, are discussed to ensure compliance and patient safety. Despite challenges such as material variability, workflow standardization, and large-scale clinical validation, evidence indicates that 3D printing significantly enhances therapeutic precision, reduces toxicity, and improves patient outcomes. This review underscores the synergy between 3D printing and AI-driven innovations as a cornerstone for next-generation radiation oncology, offering a roadmap for clinical adoption and future research.

Lithium-ion batteries (LIBs) have become the leading energy storage technology because of their high specific energy, excellent efficiency, and longer lifespan. This review offers a comprehensive overview of the lithium battery industry, covering lithium materials and the global supply chain, as well as examining traditional and sustainable extraction methods. The discussion includes the technical and environmental challenges of each extraction method, with particular emphasis on feedstock selection, which greatly influences lithium recovery efficiency, yield, and ecological impact, and capital and operating expenditures. It also investigates the growth of the global battery recycling industry and provides an outlook on innovations in this area. These innovations include recycling systems, a case study on Biomass Energy Systems Inc., and the battery chemistries needed to support a circular economy. The review highlights industrial applications of LIBs in sectors such as automotive, consumer electronics, and aerospace. Finally, it addresses supply chain and recycling challenges related to LIBs, positioning cost, environmental footprint, and regulatory compliance as central considerations for the future of the battery industry.

Medical devices play a crucial role in modern healthcare, providing innovative solutions for diagnosing, preventing, monitoring, and treating ailments. Artificial Intelligence is transforming the field of medical devices, offering unprecedented opportunities through diagnostic accuracy, personalized treatment plans, and enhancing patient outcomes. This review outlines the applications of artificial intelligence-based medical devices in healthcare specialties, especially in dentistry, medical imaging, ophthalmology, mental health, autism spectrum disorder diagnosis, oncology, and general medicine. Specifically, the review highlights advancements such as improved diagnostic accuracy, tailored treatment planning, and enhanced clinical outcomes in the above-mentioned applications. Regulatory approval remains a key issue, where medical devices must be approved or cleared by the United States Food and Drug Administration to establish their safety and efficacy. The regulatory guidance pathway for artificial intelligence-based medical devices is presented and moreover the critical technical, ethical, and implementation challenges that must be addressed for large-scale adoption are discussed. The review concludes that the intersection of artificial intelligence with the medical device domain and internet-enabled or enhanced technology, such as biotechnology, nanotechnology, and personalized therapeutics, enables an enormous opportunity to accelerate customized and patient-centered care. By evaluating these advancements and challenges, the study aims to present insights into the future trajectory of smart medical technologies and their role in advancing personalized, patient-centered care.

Additive manufacturing (AM) has revolutionized the design and production of complex geometries by offering unprecedented creative freedom over traditional manufacturing. Despite its growing prominence, AM lacks automated and standardized design rules tailored to specific AM processes, resulting in time-consuming and expert-dependent manual verification. To address these limitations, this research introduces a novel design for additive manufacturing (DfAM) framework consisting of two complementary models designed to automate the design process. The first model, based on a decision tree algorithm, evaluates part compliance with established AM design rules. A modified J48 classifier was implemented to enhance data mining accuracy by achieving a 91.25% classification performance accuracy. This model systematically assesses whether input part characteristics meet AM processing standards, thereby providing a robust tool for verifying design rules. The second model features an AM design rule engine developed with a Python-based graphical user interface (GUI). This engine generates specific recommendations for design adjustments based on part characteristics and machine compatibility, offering a user-friendly approach for identifying potential design issues and ensuring DfAM compliance. By linking part specifications to various AM techniques, this model supports both researchers and engineers in anticipating and mitigating design flaws. Overall, this research establishes a foundation for a comprehensive DfAM expert system.

In this research, a direct-write 3D-printing method was utilized for the fabrication of inter-digitized solid oxide fuel cells (SOFCs) using ceramic materials. The cathode electrode was fabricated using the LSCF (La_0.6Sr_0.2Fe_0.8Co_0.2O_3-δ) slurry loading and the Polyvinyl butyral (PVB) binder. The rheological parameters of slurries with varying LSCF slurry loading and PVB binder concentration were evaluated to determine their effect on the cathode trace performance in terms of microstructure, size, and resistance. Additionally, the dimensional shrinkage of LSCF lines after sintering was investigated to realize their influence on cathode line width and height. Moreover, the effect of the direct-write process parameters such as pressure, distance between the nozzle and substrate, and speed on the cathode line dimensions and resistance was evaluated. LSCF slurry with 50% solid loading, 12% binder, and 0.2% dispersant concentration was determined to be the optimal value for the fabrication of SOFCs using the direct-write method. The direct-write process parameters, in addition to the binder and LSCF slurry concentration ratios, had a considerable impact on the microstructure of cathode lines. Based on ANOVA findings, pressure and distance had significant effects on the cathode electrode resistance. An increase in the distance between the nozzle and substrate, speed, or extrusion pressure of the direct writing process increased the resistance of the cathode lines. These findings add to the ongoing effort to refine SOFC fabrication techniques, opening the avenues for advanced performance and efficiency of SOFCs in energy applications.

Solid oxide fuel cells (SOFCs) are a green energy technology that offers a cleaner and more efficient alternative to fossil fuels. The efficiency and utility of SOFCs can be enhanced by fabricating miniaturized component structures within the fuel cell footprint. In this research work, the parallel-connected inter-digitized design of micro-single-chamber SOFCs (µ-SC-SOFCs) was fabricated by a direct-write microfabrication technique. To understand and optimize the direct-write process, the cathode electrode slurry was investigated. Initially, the effects of dispersant Triton X-100 on LSCF (La0.6Sr0.2Fe0.8Co0.2O3-δ) slurry rheology was investigated. The effect of binder decomposition on the cathode electrode lines was evaluated, and further, the optimum sintering profile was determined. Results illustrate that the optimum concentration of Triton X-100 for different slurries was around 0.2–0.4% of the LSCF solid loading. A total of 60% of solid loading slurries had high viscosities and attained stability after 300 s. In addition, 40–50% solid loading slurries had relatively lower viscosity and attainted stability after 200 s. Solid loading and binder affected not only the slurry’s viscosity but also its rheology behavior. Based on the findings of this research, a slurry with 50% solid loading, 12% binder, and 0.2% dispersant was determined to be the optimal value for the fabricating of SOFCs using the direct-write method. This research work establishes guidelines for fabricating the micro-single-chamber solid oxide fuel cells by optimizing the direct-write slurry deposition process with high accuracy.

Microneedle (MN) technology is an optimal choice for the delivery of drugs via the transdermal route, with a minimally invasive procedure. MN applications are varied from drug delivery, cosmetics, tissue engineering, vaccine delivery, and disease diagnostics. The MN is a biomedical device that offers many advantages including but not limited to a painless experience, being time-effective, and real-time sensing. This research implements additive manufacturing (AM) technology to fabricate MN arrays for advanced therapeutic applications. Stereolithography (SLA) was used to fabricate six MN designs with three aspect ratios. The MN array included conical-shaped 100 needles (10 × 10 needle) in each array. The microneedles were characterized using optical and scanning electron microscopy to evaluate the dimensional accuracy. Further, mechanical and insertion tests were performed to analyze the mechanical strength and skin penetration capabilities of the polymeric MN. MNs with higher aspect ratios had higher deformation characteristics suitable for penetration to deeper levels beyond the stratum corneum. MNs with both 0.3 mm and 0.4 mm base diameters displayed consistent force–displacement behavior during a skin-equivalent penetration test. This research establishes guidelines for fabricating polymeric MN for high-accuracy and low-cost 3D printing.

Notably, 3D-printed flexible and wearable biosensors have immense potential to interact with the human body noninvasively for the real-time and continuous health monitoring of physiological parameters. This paper comprehensively reviews the progress in 3D-printed wearable biosensors. The review also explores the incorporation of nanocomposites in 3D printing for biosensors. A detailed analysis of various 3D printing processes for fabricating wearable biosensors is reported. Besides this, recent advances in various 3D-printed wearable biosensors platforms such as sweat sensors, glucose sensors, electrocardiography sensors, electroencephalography sensors, tactile sensors, wearable oximeters, tattoo sensors, and respiratory sensors are discussed. Furthermore, the challenges and prospects associated with 3D-printed wearable biosensors are presented. This review is an invaluable resource for engineers, researchers, and healthcare clinicians, providing insights into the advancements and capabilities of 3D printing in the wearable biosensor domain.