Mika Salmi

• D.Sc. (Tech.)
• Aalto University

This pilot study develops a process to evaluate in-situ defect detection and self-healing in Ti-6Al-4V fabricated using laser-based powder bed fusion. A tailor-made test specimen was designed and manufactured for the nanofocus tube X-ray computed tomography (XCT) system. In situ optical tomography was used to capture infrared images containing heat...

The European Union has been a forerunner in implementing sustainability policies and regulation in line with UN-led global sustainabilty treaties, such as the Paris Agreement. Becoming carbon neutral by 2050 and reducing greenhouse gas emissions-55% by 2030 are legally binding targets in EU environmental law. They offer a solid strategical foundati...

This research explores the production of polysaccharide-reinforced thin-film composites using digital light processing (DLP) 3D printing, aiming to advance options in reinforcing photocurable resin systems. Polysaccharide thin films including cellulose nanofibers (CNF), TEMPO-oxidized cellulose nanofibers (ToCNF), chitin nanofibers (ChNF), and elec...

Despite advances in prosthesis materials, operating microscopes and surgical techniques during the last 50 years, long-lasting hearing improvement remains a challenge in ossicular chain reconstruction. Failures in the reconstruction are mainly due to inadequate length or shape of the prosthesis, or defects in the surgical procedure. 3D-printed midd...

This paper introduces a novel 4D printing approach for dynamic displays, using thermochromic-PLA composites embedded with FeCrAl wires activated by Joule heating. Previous studies struggled with high energy consumption, heat bleed, and slow activation. By embedding continuous resistance wires directly within the thermochromic-plastic matrix, locali...

Additive manufacturing (AM), more familiarly known as 3D printing, has also been postulated as an advantageous manufacturing technology from a sustainability perspective. A few of these technologies, such as laser powder bed fusion (PBF-LB), have been increasingly used in industrial production. Considerable performance and efficiency increases are...

Purpose This works provides a thorough understanding of the challenges and opportunities associated with Additive Manufacturing (AM) adoption in the medical sector. Through this analysis, we aim to better understand when to adopt AM, how to do so, and how such adoption might change in the future. Design/methodology/approach This research first con...

3D printing has been adopted into routine use for certain medical applications, but more widespread usage has been hindered by, among other things, unclear legislation. We performed an analysis, using legal doctrinal study and legal informatics, of relevant EU legislation and case law in four issues relevant to medical 3D printing (excluding biopri...

Highlights What are the main findings? For current supply chain disruptions, only AM production of entire orthopedic shoes is viable. Hybrid solutions, where only components or tools are AM produced, seem not viable. Low prices and a perfect digital design are hard requirements for an AM SC. What is the implication of the main finding? Research ho...

3D-printing, also known as additive manufacturing, has enabled the production of dynamically shaped objects often customized for specific applications. Many applications, such as sensors in the aerospace industry, have demanding mass and volume requirements or need to work in challenging environments that necessitate electronics to be protected. Th...

Background In otosurgical training, cadaveric temporal bones are primarily used to provide a realistic tactile experience. However, using cadaveric temporal bones is challenging due to their limited availability, high cost, and potential for infection. Utilizing current three-dimensional (3D) technologies could overcome the limitations associated w...

In this study, a set of 316 L stainless steel test specimens was additively manufactured by laser-based Powder Bed Fusion. The process parameters were varied for each specimen in terms of laser scan speed and laser power. The objective was to use a narrow band of parameters well inside the process window, demonstrating detailed parameter engineerin...

The objective of this study is to develop and evaluate self-sensing capabilities in additively manufactured parts by embedding conductive elements that are copper and continuous carbon fiber. Two sets of test specimen were manufactured using a custom g-code on material extrusion-based Anisoprint A4 machine. Each set contained copper and continuous...

With the growing concerns of environmental issues and awareness of sustainable materials and energy, industrial hemp has been proposed as one of the strategies to react to the ecological crisis and challenges that are caused by the transition from the original power plant to a sustainable ecosystem in Midland Ireland, with the support Just Transiti...

The aim of this study is to deploy machine learning (ML) classification methods to detect defective regions in additive manufacturing, colloquially known as 3D printing, particularly for the laser-based powder bed fusion process. A custom-designed test specimen composed of 316L was manufactured using EOS M 290 machine. Multinomial logistic regressi...

Shape memory polymer composites (SMPCs) have gained attention for their shape memory effects and wide-ranging applications. Understanding the bending shape recovery characteristics of 3D printed SMPCs is crucial for optimizing their performance. This study focuses on investigating the influence of different fiber orientations of continuous carbon f...

Additive manufacturing (AM) has shown to have a high potential to produce spare parts on demand. However, the use of AM to produce spare parts on demand faces challenges related to material availability, quality, part size, cost, and pre- and post-processing operations. From existing literature, most studies focus on a single use case. Other studie...

In the last years, Additive manufacturing (AM) has gained increasing interest among practitioners in manufacturing personalized medical products. Researchers have consequently aligned to this increasing interest from practice, trying to support the development of AM for personalized medical products. However, researchers are currently overlooking o...

Introduction: 3D printing has quickly found many applications in medicine. However, as with any new technology the regulatory landscape is struggling to stay abreast. Unclear legislation or lack of legislation has been suggested as being one hindrance for wide-scale adoption. Methods: A scoping review was performed in PubMed, Web of Science, SCOPUS...

Additive manufacturing (AM) has shown to be a promising method for creating high-performance plastic components. In space, harsh environmental conditions such as vacuum ultraviolet radiation and significant temperature changes cause the degradation of polymers and static electricity buildup on the surface of non-conductive components. This study ex...

Laser powder bed fusion (LPBF) has become an established method for manufacturing end-use metal components. Exploiting the geometric freedom of additive manufacturing (AM) offers broad possibilities for part optimization and enables performance enhancements across industry sectors. However, part shape and feature size have been found to locally aff...

Additive manufacturing (AM) has been considered for distributed manufacturing. However, the consideration has usually concerned AM in general, not specific AM processes. This paper will look at the properties of different processes for distributed manufacturing from the perspective of the AM process and materials, post-processing, the requirements...

Purpose: Introducing additive manufacturing (AM) in a multinational corporation with a global spare parts operation requires tools for a dynamic supplier selection, considering both cost and delivery performance. In the switchover to AM from conventional manufacturing, the objective of this study is to find situations and ways to improve the spare...

Vat photopolymerization is the oldest and popular additive manufacturing technique, which can print metal and ceramic parts quickly with high dimensional accuracy. This study successfully produced a metallic alloy from elemental powders by Digital Light Processing (DLP) method. Ni-Ti-Cu powders were blended in a curable resin with a specific ratio....

The COVID-19 pandemic has exponentially accelerated the use of 3D printing (3DP) technologies in healthcare. Surprisingly, though, we have seen hardly any public intellectual property right (IPR) disputes concerning the 3D-printed medical equipment produced to cope with this crisis. Yet it can be assumed that a great variety of IPRs could potential...

KEYWORDS additive manufacturing, 3D printing, 3D medical imaging, 3d modeling and 3d models, medical models, biomaterials Editorial on the Research Topic Creative digital design and manufacturing in medicine Digitalization continues to take significant developmental steps in medicine. Simultaneously methods for digital design including 3D modeling...

Additive manufacturing (AM) or, more commonly, 3D printing has grown in double digits in past years. It has shown its potential example in the medical, automotive, aerospace, and spare part sectors. Personal manufacturing, complex and optimized parts, short series manufacturing and local on-demand manufacturing are some of the current benefits. The...

Additive Manufacturing (AM) has the potential to revolutionize key aspects of Military Logistics and partnerships between governmental and industrial organizations. Extreme outsourcing of key capabilities has created complex and deep hybrid organizations between armed forces and the private sector. In this study, the internal and external effects a...

Additive manufacturing (AM) or, more commonly, 3D printing is one of the fundamental elements of Industry 4.0. and the fourth industrial revolution. It has shown its potential example in the medical, automotive, aerospace, and spare part sectors. Personal manufacturing, complex and optimized parts, short series manufacturing and local on-demand man...

A non-equiatomic AlCoCr0.75Cu0.5FeNi alloy has been identified as a potential high strength alloy, whose microstructure and consequently properties can be widely varied. In this research, the phase structure, hardness, and magnetic properties of AlCoCr0.75Cu0.5FeNi alloy fabricated by laser powder bed fusion (LPBF) are investigated. The results dem...

Additive manufacturing (AM), or commonly, 3D printing, has been witnessed in various applications and purposes such as industrial applications in consumer products, energy, aerospace, medical, spare parts [...]

Additive manufacturing or, more commonly, 3D printing is one of the fundamental elements of Industry 4.0. and the fourth industrial revolution [...]

Laser powder bed fusion (L-PBF) is used to produce foam-like Ni-Mn-Ga with tailored microscale and mesoscale features. Ni50-Mn28.2-Ga21.8 (at%) powder was gas atomised and processed in an L-PBF system with a range of energy density from 26.24 and 44.90 J/mm³. We characterised microscale and mesoscale properties, such as the chemical composition, cr...

The additive manufacturing (AM) methods, selective laser sintering (SLS) and multi jet fusion (MJF), are increasingly used for end-use polymer parts. Chemical reactions caused by ionizing radiation and catalyzed by oxygen, moisture, and heat are known to degrade the polymer structure, result in visual defects, and loss of mechanical properties. How...

Many fields including the aerospace industry have shown increased interest in the use of plastics to lower the mass of systems. However, the use of plastics in space can be challenging for a number of reasons. Ultraviolet radiation, atomic oxygen and other phenomena specifically associated with space cause the degradation of polymers. Here we show...

Additive manufacturing, or more commonly 3D printing, has been recently established as one of the most advanced technologies for fabricating multi-material parts. In this work, the possibility of manufacturing multimetal parts by material extrusion process was studied for the first time. Three types of samples, named mixed, coupled and graded, resu...

Metals made by additive manufacturing (AM) have intensely augmented over the past decade for customizing complex structured products in the aerospace industry, automotive, and biomedical engineering. However, for AM fabricated steels, the correlation between the microstructure and mechanical properties is yet a challenging task with limited reports...

Centralized supply chains (SCs) are prone to disruption, which makes them a risky choice for medical equipment production. Additive manufacturing (AM) allows for production localization and improvements in SC resilience. However, the comparative competitiveness of a localized SC from the time and cost perspective is still unclear. In this study, we...

Laser powder bed fusion additive manufacturing is used for demanding applications in industries such as aerospace. However, machine-specific, optimized process conditions and parameters are required to assure consistent part quality. In addition, differences in supplied powder can cause variation in the mechanical properties of the final parts. In...

The general objective of AM-NPP is to increase the knowledge of Finnish stakeholders on the use of Additive Manufacturing (AM), in particular Laser Powder Bed Fusion (L-PBF), therefore ensuring the safe use of additively manufactured metallic components in the nuclear sector. It is a technology which is showing a lot of applicability potential, e.g...

Better visualization of tumor structure and orientation are needed in the postoperative setting. We aimed to assess the feasibility of a system in which oral and oropharyngeal tumors are resected, photographed, 3D modeled, and printed using additive manufacturing techniques. Three patients diagnosed with oral/oropharyngeal cancer were included. All...

Purpose Although additive manufacturing (AM) has been demonstrated to have significant potential in improving spare part delivery operations and has been adopted to a degree in the aviation and automotive industries, its use in spare part production is still limited in other fields due to a variety of implementation barriers. The purpose of this ar...

Medical imaging often presents objects in three-dimensional (3D) form to provide better visual understanding. In contrast, histopathology is typically presented as two-dimensional (2D). Our objective was to present the tumor dimensions in 3D by creating a 3D digital model of it and so demonstrate the location of the tumor and the histological slice...

Additive manufacturing (AM, 3D printing) is used in many fields and different industries. In the medical and dental field, every patient is unique and, therefore, AM has significant potential in personalized and customized solutions. This review explores what additive manufacturing processes and materials are utilized in medical and dental applicat...

Featured Application The customizable clip system opens new possibilities for occupational health professionals since the basic design can be altered to hold different kinds of samplers and tools. The solution is shared using an open source methodology to allow for distributed manufacturing of the free designs. Abstract Design for additive manufac...

16 Undoubtedly, the main advantage of the additive manufacture technology is to allow building 17 miniature structural parts with a large degree of complexity such as to replicate structural details of 18 real-scale marine structures. This work presents a new technique for reproducing the structural 19 response of large-scale thin-walled metallic s...

The purpose of this article is to present a design for additive manufacturing assignment focused on creativity rather than functionality and to analyze its results (N = 70) acquired during five years. The assignment teaches the unique advantages of additive manufacturing to engineering students and encourages learning from failure to achieve design...

The COVID-19 pandemic has caused a surge of demand for medical supplies and spare parts, which has put pressure on the manufacturing sector. As a result, 3D printing communities and companies are currently operating to ease the breakdown in the medical supply chain. If no parts are available, 3D printing can potentially be used to produce time-crit...

Substantial progress has been made in the last decades to computationally model the structural response of marine structures subjected to collision and grounding accidents. The finite element method stands out as the most reliable and robust technique within other tools for this purpose. However, there are still some complex physical aspects arduou...

Featured Application Accuracy of additively manufactured implants for clinical surgery. Abstract In craniomaxillofacial surgical procedures, an emerging practice adopts the preoperative virtual planning that uses medical imaging (computed tomography), 3D thresholding (segmentation), 3D modeling (digital design), and additive manufacturing (3D prin...

The scope of this research is to characterize and optimize the vibration-assisted ball burnishing of additively manufactured 18% Nickel Maraging steel for tooling applications. We evaluate the suitability of vibration-assisted ball burnishing as an alternative method to post-process additively manufactured tool steel. To do so, we assessed a single...

The topic of spare parts is always challenging for operations, with the need to balance service provision with cost minimization for the full lifecycle of the product. This chapter provides a detailed discussion on the application of 3D printing for the manufacture of spare parts. It examines the characteristics which make 3D printing a viable prop...

Metal-fused filament fabrication is gaining traction due to its low cost and high availability compared to metal powder bed fusion. However, the achievable mechanical properties and effects of shrinkage of this process should be understood thoroughly before it can be implemented as a direct digital manufacturing technology. This study investigates...

The purpose of this chapter is to verify the conceptual benefits of the implementation of additive manufacturing (AM) in spare part supply chains from the point of view of the industry. Focus group interviews consisting of five sessions and 46 experts in manufacturing were conducted for this study. The focus group interviews served to identify the...

Considerable advances have been made in the last decades to computationally model the structural response of marine structures subjected to collisions and grounding events. Within existing numerical tools, finite element method stands out as one of the most complete, reliable and robust technique. However, there are still some complex aspects diffi...

Background The fit of the allograft is a particular concern in fresh cadaveric osteochondral allograft (FOCA) surgery. Digital design and fabrication were utilized in conjunction with traditional surgery to enable efficient discovery and reproduction of appropriately dimensioned allograft. Methods A patient with large osteochondral defects in the l...

Increasingly, metal parts made by additive manufacturing are produced using powder bed fusion (PBF). In this paper we report upon the combined effects of PBF parameters, including power and scan speed, in layer-by-layer manufacturing of gas atomized non-modulated (NM) Ni-Mn-Ga alloy. The effects of process parameters upon PBF is studied by applying...

Background and aims: Additive manufacturing or three-dimensional printing is a novel production methodology for producing patient-specific models, medical aids, tools, and implants. However, the clinical impact of this technology is unknown. In this study, we sought to characterize the clinical adoption of medical additive manufacturing in Finland...

Glottal inverse filtering (GIF) refers to technology to estimate the source of voiced speech, the glottal flow, from speech signals. When a new GIF algorithm is proposed, its accuracy needs to be evaluated. However, the evaluation of GIF is problematic because the ground truth, the real glottal volume velocity signal generated by the vocal folds, c...

Additive manufacturing is a fast-growing field of industry that enables production of complex shapes and components. Topological optimisation is a shape optimisation methodology that often takes advantage of these new manufacturing possibilities. However, casting is not often taken into proper consideration when topologicals optimised components ar...

Additive manufacturing of digital spare parts offers promising new possibilities for companies to drastically shorten lead times and to omit storage costs. However, the concept of digital spare parts has not yet gained much footing in the manufacturing industry. This study aims to identify grounds for its selective rejection. Conducted from a corpo...

The purpose of this paper is to verify the conceptual benefits of the implementation of additive manufacturing (AM) in spare part supply chains from the point of view of industry. Focus group interviews consisting of five sessions and 46 experts in manufacturing were conducted for this study. The focus group interviews served to identify the issues...

The purpose of this study is to demonstrate the ability of additive manufacturing, also known as 3D printing, to produce effective drug delivery devices and implants that are both identifiable, as well as traceable. Drug delivery devices can potentially be used for drug release in the direct vicinity of target tissues or the selected medication rou...

The aim of this study is to describe the steps needed for producing medical models by 3D printing. Further, the timeline for various 3D printing processes and related process steps and their estimated cost structure will be discussed. Computed tomography images were used as a starting point for the present case and a 3D model of skull and jaw was r...

Space technology has been an early adopter of additive manufacturing (AM) as a way of quickly producing relatively complex systems and components that would otherwise require expensive and custom design and production. Space as an environment and long-term survivability pose challenges to materials used in AM and these challenges need to be address...

Tämä raportti on kooste Aalto-yliopiston ja Teknologian tutkimuskeskus VTT:n johtaman ja toteuttaman Digitaaliset varaosat -tutkimusprojektin tuloksista. Projektin päätavoitteena oli luoda digitaalisten varaosien liiketoimintakonsepti ja rakentaa edellytykset toimivalle verkos-tolle, selvittää 3D-tulostusprosesseilla valmistettujen varaosien suorit...

This report is a compilation of the results of the Digital Spare Parts research project, managed and implemented by Aalto University and VTT Technical Research Centre of Finland. The main goal of the project was to create a business concept for digital spare parts and to lay down the foundations for a functional network, analyse the current and fut...

Spare parts for products that are at the end of their life cycles, but still under warranty, are logistically difficult because they are commonly not stored in the central warehouse. These uncommon spare parts occupy valuable space in smaller inventories and take a long time to be transported to the point of need, thus delaying the repair process....

The objective of this research is to define an optimal innovation policy and funding strategy to improve Additive Manufacturing (AM) capabilities in Finnish companies. To do so, we present an international review of innovation programs in the area of AM. In addition, the study replied upon a survey prepared to evaluate factors for AM implementation...

The purpose of this paper is to investigate the post-processing of Co-Cr and 316L stainless steel components made by additive manufacturing (AM) using ultrasonic burnishing. AM is able to produce functional parts for medical and industrial applications; however, the parts require support removal and post-processing to achieve the technical requirem...

Custom-designed patient-specific implants and reconstruction plates are to date commonly manufactured using two different additive manufacturing (AM) technologies: direct metal laser sintering (DMLS) and electron beam melting (EBM). The purpose of this investigation was to characterize the surface structure and to assess the cytotoxicity of titaniu...