High strength, low stiffness, porous NiTi with superelastic properties

Actuation for flexible and stretchable microdevices

Flexible and stretchable microdevices incorporate highly deformable structures, facilitating precise functionality at the micro- and millimetre scale. Flexible microdevices have showcased extensive utility in the fields of biomedicine, microfluidics, and soft robotics. Actuation plays a critical role in transforming energy between different forms, ensuring the effective operation of devices. However, when it comes to actuating flexible microdevices at the small millimetre or even microscale, translating actuation mechanisms from conventional rigid large-scale devices is not straightforward. The recent development of actuation mechanisms leverages the benefits of device flexibility, particularly in transforming conventional actuation concepts into more efficient approaches for flexible devices. Despite many reviews on soft robotics, flexible electronics, and flexible microfluidics, a specific and systematic review of the actuation mechanisms for flexible and stretchable microdevices is still lacking. Therefore, the present review aims to address this gap by providing a comprehensive overview of state-of-the-art actuation mechanisms for flexible and stretchable microdevices. We elaborate on the different actuation mechanisms based on fluid pressure, electric, magnetic, mechanical, and chemical sources, thoroughly examining and comparing the structure designs, characteristics, performance, advantages, and drawbacks of these diverse actuation mechanisms. Furthermore, the review explores the pivotal role of materials and fabrication techniques in the development of flexible and stretchable microdevices. Finally, we summarise the applications of these devices in biomedicine and soft robotics and provide perspectives on current and future research.

Porous metal implants: processing, properties, and challenges

Porous and functionally graded materials have seen extensive applications in modern biomedical devices-allowing for improved site-specific performance; their appreciable mechanical, corrosive, and biocompatible properties are highly sought after for lightweight and high-strength load-bearing orthopedic and dental implants. Examples of such porous materials are metals, ceramics, and polymers. Although, easy to manufacture and lightweight, porous polymers do not inherently exhibit the required mechanical strength for hard tissue repair or replacement. Alternatively, porous ceramics are brittle and do not possess the required fatigue resistance. On the other hand, porous biocompatible metals have shown tailorable strength, fatigue resistance, and toughness. Thereby, a significant interest in investigating the manufacturing challenges of porous metals has taken place in recent years. Past research has shown that once the advantages of porous metallic structures in the orthopedic implant industry have been realized, their biological and biomechanical compatibility-with the host bone-has been followed up with extensive methodical research. Various manufacturing methods for porous or functionally graded metals are discussed and compared in this review, specifically, how the manufacturing process influences microstructure, graded composition, porosity, biocompatibility, and mechanical properties. Most of the studies discussed in this review are related to porous structures for bone implant applications; however, the understanding of these investigations may also be extended to other devices beyond the biomedical field.

Improving Biocompatibility for Next Generation of Metallic Implants

The increasing need for joint replacement surgeries, musculoskeletal repairs, and orthodontics worldwide prompts emerging technologies to evolve with healthcare's changing landscape. Metallic orthopaedic materials have a shared application history with the aerospace industry, making them only partly efficient in the biomedical domain. However, suitability of metallic materials in bone tissue replacements and regenerative therapies remains unchallenged due to their superior mechanical properties, eventhough they are not perfectly biocompatible. Therefore, exploring ways to improve biocompatibility is the most critical step toward designing the next generation of metallic biomaterials. This review discusses methods of improving biocompatibility of metals used in biomedical devices using surface modification, bulk modification, and incorporation of biologics. Our investigation spans multiple length scales, from bulk metals to the effect of microporosities, surface nanoarchitecture, and biomolecules such as DNA incorporation for enhanced biological response in metallic materials. We examine recent technologies such as 3D printing in alloy design and storing surface charge on nanoarchitecture surfaces, metal-on-metal, and ceramic-on-metal coatings to present a coherent and comprehensive understanding of the subject. Finally, we consider the advantages and challenges of metallic biomaterials and identify future directions.

Novel Method for the Production of Titanium Foams to Reduce Stress Shielding in Implants

Titanium foams have potential applications in orthopedic and dental implants because of their low elastic modulus and good bone in-growth properties. In the present study, a novel method for the preparation of three-dimensional interconnected microporous titanium foams has been developed. This method is based on the insertion of a filler metal into the titanium metal by arc melting, followed by its removal by an electrochemical dealloying process for the development of foams. Complete removal of the filler metal by the electrochemical dealloying process was confirmed by an X-ray diffractometry (XRD) analysis, whereas scanning electron microscopy (SEM) analysis of the developed foams showed the development of interconnected porosity. Ti foams with different levels of porosities were successfully developed by varying the amount of the filler metal. Mechanical and thermal characterizations of the developed foams were carried out using compression testing and laser flash apparatus, respectively. The yield strength and elastic modulus of the developed foams were found to decrease by increasing the volume fraction of pores. The elastic modulus of the developed titanium foams (15.5-36 GPa) was found to be closer to that of human bones, whereas their yield strength (147-170 MPa) remained higher than that of human bones. It is therefore believed that the developed Ti foams can help in reducing the problem of stress shielding observed in orthopedic implants. The thermal diffusivity of the developed foams (4.3-0.69 mm2/s) was found to be very close to that of human dentine.

Chemical Polishing of Additively Manufactured, Porous, Nickel-Titanium Skeletal Fixation Plates

Nickel-titanium (NiTi) alloys have shown promise for a variety of biomedical applications because of their unique properties of shape memory, superelasticity, and low modulus of elasticity (Young's modulus). Nevertheless, NiTi bulk components cannot be easily machined (e.g., CNC, rolling, grinding, casting, or press molding) due to their thermomechanical sensitivity as well as inherent superelasticity and shape memory. Thus, powder bed fusion (PBF) additive manufacturing has been used to successfully fabricate NiTi medical devices that match the geometric and mechanical needs of a particular patient's condition. However, NiTi PBF fabrication leaves unmelted particles from the source powder adhered to external surfaces, which cause minor dimensional inaccuracy, increase the risk of mechanical failure, and once loose, may irritate or inflame surrounding tissues. Therefore, there is a need to develop a chemical polishing (cleaning) technique to remove unmelted powder from the surfaces of PBF-fabricated implants, especially from inner surfaces that are difficult to access with mechanical polishing tools. This technique is especially useful for highly porous devices printed at high resolution. In this study, a chemical polishing method utilizing HF/HNO₃ solution was used to remove loosely attached (i.e., unmelted) powder particles from surfaces of porous, skeletal fixation plates manufactured by PBF AM. It was observed that 7 min of polishing in an HF/HNO₃ solution comprising 7.5 HF: 50 HNO₃: 42.5 H₂O enabled successful removal of all relatively loose and unmelted powder particles. A microcomputed tomography study examination found that the volumetric accuracy of the polished skeletal fixation plates was ±10% compared with the computer-aided design (CAD) model from which it was rendered. This postprocessing chemical polishing protocol is also likely to be useful for removing loose powder, while maintaining CAD model accuracy and mechanical stability for other complexly shaped, porous, three-dimensional (3D), printed NiTi devices.

Heat Treatment of NiTi Alloys Fabricated Using Laser Powder Bed Fusion (LPBF) from Elementally Blended Powders

The use of elemental metallic powders and in situ alloying in additive manufacturing (AM) is of industrial relevance as it offers the required flexibility to tailor the batch powder composition. This solution has been applied to the AM manufacturing of nickel-titanium (NiTi) shape memory alloy components. In this work, we show that laser powder bed fusion (LPBF) can be used to create a Ni55.7Ti44.3 alloyed component, but that the chemical composition of the build has a large heterogeneity. To solve this problem three different annealing heat treatments were designed, and the resulting porosity, microstructural homogeneity, and phase formation was investigated. The heat treatments were found to improve the alloy's chemical and phase homogeneity, but the brittle NiTi2 phase was found to be stabilized by the 0.54 wt.% of oxygen present in all fabricated samples. As a consequence, a Ni2Ti4O phase was formed and was confirmed by transmission electron microscopy (TEM) observation. This study showed that pore formation in in situ alloyed NiTi can be controlled via heat treatment. Moreover, we have shown that the two-step heat treatment is a promising method to homogenise the chemical and phase composition of in situ alloyed NiTi powder fabricated by LPBF.

Design and Mechanical Compatibility of Nylon Bionic Cancellous Bone Fabricated by Selective Laser Sintering

In order to avoid the stress shielding phenomenon in orthopedic bionic bone implantation, it is necessary to consider the design of mechanical compatible implants imitating the host bone. In this study, we developed a novel cancellous bone structure design method aimed at ensuring the mechanical compatibility between the bionic bone and human bone by means of computer-aided design (CAD) and finite element analysis technology (specifically, finite element modeling (FEM)). An orthogonal lattice model with volume porosity between 59% and 96% was developed by means of CAD. The effective equivalent elastic modulus of a honeycomb structure with square holes was studied by FEM simulation. With the purpose of verifying the validity of the cancellous bone structure design method, the honeycomb structure was fabricated by selective laser sintering (SLS) and the actual equivalent elastic modulus of the honeycomb structure was measured with a uniaxial compression test. The experimental results were compared with the FEM values and the predicted values. The results showed that the stiffness values of the designed structures were within the acceptable range of human cancellous bone of 50–500 MPa, which was similar to the stiffness values of human vertebrae L1 and L5. From the point of view of mechanical strength, the established cellular model can effectively match the elastic modulus of human vertebrae cancellous bone. The functional relationship between the volume porosity of the nylon square-pore honeycomb structure ranging from 59% to 96% and the effective elastic modulus was established. The effect of structural changes related to the manufacture of honeycomb structures on the equivalent elastic modulus of honeycomb structures was studied quantitatively by finite element modeling.

Porous Titanium Cylinders Obtained by the Freeze-Casting Technique: Influence of Process Parameters on Porosity and Mechanical Behavior

The discrepancy between the stiffness of commercially pure titanium and cortical bone tissue compromises its success as a biomaterial. The use of porous titanium has been widely studied, however, it is still challenging to obtain materials able to replicate the porous structure of the bones (content, size, morphology and distribution). In this work, the freeze-casting technique is used to manufacture cylinders with elongated porosity, using a home-made and economical device. The relationship between the processing parameters (diameter and material of the mold, temperature gradient), microstructural features and mechanical properties is established and discussed, in terms of ensuring biomechanical and biofunctional balance. The cylinders have a gradient porosity suitable for use in dentistry, presenting higher Young’s modulus at the bottom, near the cold spot and, therefore better mechanical resistance (it would be in contact with a prosthetic crown), while the opposite side, the hot spot, has bigger, elongated pores and walls.

Influence of the Compaction Pressure and Sintering Temperature on the Mechanical Properties of Porous Titanium for Biomedical Applications

In the present work, the use of porous titanium is proposed as a solution to the difference in stiffness between the implant and bone tissue, avoiding the bone resorption. Conventional powder metallurgical technique is an industrially established route for fabrication of this type of material. The results are discussed in terms of the influence of compaction pressure and sintering temperature on the porosity (volumetric fraction, size, and morphology) and the quality of the sintering necks. A very good agreement between the predicted values obtained using a simple 2D finite element model, the experimental uniaxial compression behavior, and the analytical model proposed by Nielsen, has been found for both the Young’s modulus and the yield strength. The porous samples obtained by the loose sintering technique and using temperatures between 1000 °C −1100 °C (about 40% of total porosity) are recommended for achieving a suitable biomechanical behavior for cortical bone partial replacement.

Mechanical performance of highly permeable laser melted Ti6Al4V bone scaffolds

Critically engineered stiffness and strength of a scaffold are crucial for managing maladapted stress concentration and reducing stress shielding. At the same time, suitable porosity and permeability are key to facilitate biological activities associated with bone growth and nutrient delivery. A systematic balance of all these parameters are required for the development of an effective bone scaffold. Traditionally, the approach has been to study each of these parameters in isolation without considering their interdependence to achieve specific properties at a certain porosity. The purpose of this study is to undertake a holistic investigation considering the stiffness, strength, permeability, and stress concentration of six scaffold architectures featuring a 68.46-90.98% porosity. With an initial target of a tibial host segment, the permeability was characterised using Computational Fluid Dynamics (CFD) in conjunction with Darcy's law. Following this, Ashby's criterion, experimental tests, and Finite Element Method (FEM) were employed to study the mechanical behaviour and their interdependencies under uniaxial compression. The FE model was validated and further extended to study the influence of stress concentration on both the stiffness and strength of the scaffolds. The results showed that the pore shape can influence permeability, stiffness, strength, and the stress concentration factor of Ti6Al4V bone scaffolds. Furthermore, the numerical results demonstrate the effect to which structural performance of highly porous scaffolds deviate, as a result of the Selective Laser Melting (SLM) process. In addition, the study demonstrates that stiffness and strength of bone scaffold at a targeted porosity is linked to the pore shape and the associated stress concentration allowing to exploit the design freedom associated with SLM.

Biocompatibility and Clinical Application of Porous TiNi Alloys Made by Self-Propagating High-Temperature Synthesis (SHS)

Porous TiNi alloys fabricated by self-propagating high-temperature synthesis (SHS) are biomaterials designed for medical application in substituting tissue lesions and they were clinically deployed more than 30 years ago. The SHS process, as a very fast and economically justified route of powder metallurgy, has distinctive features which impart special attributes to the resultant implant, facilitating its integration in terms of bio-mechanical/chemical compatibility. On the phenomenological level, the fact of high biocompatibility of porous SHS TiNi (PTN) material in vivo has been recognized and is not in dispute presently, but the rationale is somewhat disputable. The features of the SHS TiNi process led to a multifarious intermetallic Ti4Ni2(O,N,C)-based constituents in the amorphous-nanocrystalline superficial layer which entirely conceals the matrix and enhances the corrosion resistance of the unwrought alloy. In the current article, we briefly explore issues of the high biocompatibility level on which additional studies could be carried out, as well as recent progress and key fields of clinical application, yet allowing innovative solutions.

Osteoarthritic process modifies expression response to NiTi alloy presence

Nickel-titanium alloy (nitinol, NiTi) is a biomaterial with unique thermal shape memory, superelasticity and high damping properties. Therefore NiTi has been used in medical applications. In this in vitro study, the effect of NiTi alloy (with two surface modifications - helium and hydrogen) on gene expression profile of selected interleukins (IL-1β, IL-6 and IL-8) and matrix metalloproteinases (MMP-1 and MMP-2) in human physiological osteoblasts and human osteoarthritic osteoblasts was examined to respond to a question of the different behavior of bone tissue in the implantation of metallic materials in the presence of cells affected by the osteoarthritic process. The cells were cultivated in contact with NiTi and with or without LPS (bacterial lipolysaccharide). Changes in expression of target genes were calculated by 2^-ΔΔCt method. An increased gene expression of IL-1β in osteoarthritic osteoblasts, with even higher expression in cells collected directly from the metal surface was observed. In case of physiological osteoblasts, the change in expression was detected after LPS treatment in cells surrounding the disc. Higher expression levels of IL-8 were observed in osteoarthritic osteoblasts after NiTi treatment in contact with alloy, and in physiological osteoblasts without relation to location in combination of NiTi and LPS. IL-6 was slightly increased in physiological osteoblastes after application of LPS. MMP-1 expression level was obviously significantly higher in osteoarthritic osteoblasts with differences regarding the metal surface and location. MMP-2 expression was decreased in both cell lines after LPS treatment. In conclusion, results of present study show that the NiTi alloy and the treatment by LPS, especially repeated doses of LPS, change the gene expression of selected ILs and MMPs in human osteoblast cell cultures. Some of the changes were depicted solely to osteoarthritic osteoblasts.

Influences of Compression Ratios on Sound Absorption Performance of Porous Nickel–Iron Alloy

The improvement of sound absorption performance of porous metal is a focus of research in the field of noise reduction. Influences of compression ratios on sound absorption performance of a porous nickel–iron (Ni–Fe) alloy were investigated. The samples were compressed with ratios from 10% to 80% at an interval of 10%. Based on the standing wave method, sound absorption coefficients of compressed samples with different thicknesses were obtained. It could be found that with the same compression ratio, sound absorption performance was improved with the increase of thickness. Based on the modified Johnson–Allard model with a correction factor, the sound absorption coefficient of the porous Ni–Fe with a thickness of 20 mm for different compression ratios was derived, whose aim was to quantificationally analyze influences of the compression ratio. The results indicated that the sample with a compression ratio of 70% exhibited optimal sound absorption performance, and its average sound absorption coefficient reached 88.97% in a frequency range of 1000–6000 Hz. Meanwhile, the section morphologies of compressed samples were investigated by a scanning electron microscope, which studied the sound absorption performance by analyzing structures of the porous Ni–Fe samples with different compression ratios. The obtained achievements will promote the application of the porous Ni–Fe alloy in the field of acoustics.

A comparative study of the effect of submicron porous and smooth ultrafine-grained Ti-20Mo surfaces on osteoblast responses

The surface of an orthopaedic implant plays a crucial role in determining the adsorption of proteins and cell functions. A detailed comparative study has been made of the in vitro osteoblast responses to coarse-grained (grain size: 500 μm), ultrafine-grained (grain size: 100 nm), coarse-porous (pore size: 350 nm), and fine-porous (pore size: 155 nm) surfaces of Ti-20Mo alloy. The purpose was to provide essential experimental data for future design of orthopaedic titanium implants for rapid osseointegration. Systematic original experimental data was produced for each type of surfaces in terms of surface wettability, cell morphology, adhesion, growth, and differentiation. Microscopic evidence was collected to reveal the detailed interplay between each characteristic surface with proteins or cells. Various new observations were discussed and compared with literature data. It was concluded that the coarse-porous surfaces offered the optimum topographical environment for osteoblasts and that the combination of ultrafine grains and considerable grain boundary areas is not an effective way to enhance cell growth and osteogenic capacity. Moreover, pore features (size and depth) have a greater effect than smooth surfaces on cell growth and osteogenic capacity. It proves that cells can discern the difference in pore size in the range of 100-350 nm. © 2018 Wiley Periodicals, Inc. J Biomed Mater Res Part A: 106A: 2020-2033, 2018.

Shape memory response of porous NiTi shape memory alloys fabricated by selective laser melting

Porous NiTi scaffolds display unique bone-like properties including low stiffness and superelastic behavior which makes them promising for biomedical applications. The present article focuses on the techniques to enhance superelasticity of porous NiTi structures. Selective Laser Melting (SLM) method was employed to fabricate the dense and porous (32-58%) NiTi parts. The fabricated samples were subsequently heat-treated (solution annealing + aging at 350 °C for 15 min) and their thermo-mechanical properties were determined as functions of temperature and stress. Additionally, the mechanical behaviors of the samples were simulated and compared to the experimental results. It is shown that SLM NiTi with up to 58% porosity can display shape memory effect with full recovery under 100 MPa nominal stress. Dense SLM NiTi could show almost perfect superelasticity with strain recovery of 5.65 after 6% deformation at body temperatures. The strain recoveries were 3.5, 3.6, and 2.7% for samples with porosity levels of 32%, 45%, and 58%, respectively. Furthermore, it was shown that Young's modulus (i.e., stiffness) of NiTi parts can be tuned by adjusting the porosity levels to match the properties of the bones.

Different models for simulation of mechanical behaviour of porous materials

Commercially pure Titanium (cpTi) and its alloys are the most successful metallic biomaterials for bone replacement, due to its excellent biomechanical and biofunctional balance. However, these materials have higher elastic modulus when compared with bone, leading to the stress-shielding phenomenon and promoting bone resorption. Development of porous implants with low elastic modulus, providing a good mechanical and functional balance (suitable mechanical strength and optimum osseointegration), is the focus of emergent research in advanced Ti-based alloy biomaterials. With the aim of understanding the mechanical behaviour of porous materials with relation to the porosity level and the porous morphology, a new improved model with three different versions have been developed in this work. The proposed FE model combines the simplicity of a 2D periodic geometry with the complex information of the pore morphology extracted from experimentation. The methodology to generate the 2D simulated microstructure is based on a series of nxn pores distributed in a square matrix. The different versions of the model differ in the way of building the porous geometry. In the first version of the model ("Basic-Pattern Model"), the pores are supposed to be circular and periodically distributed in the matrix, following a perfect pattern. The second version of the model ("Pattern Model") is similar to the previous one, but with elliptic pores with a morphology randomly generated, following statistical information from experiments. In the third version ("Semi-random Model"), a controlled random distribution of the pores is obtained by including a randomness factors in both directions. By making use of the proposed FE model with its different versions, five different porous titanium obtained by the space-holders technique (with porosities θ = 28%, 37%, 47%, 57% and 66%) have been modeled based on experimental information of the pore morphology, and its macroscopic mechanical behaviour has been simulated, showing relatively good agreement with experimental results.

Harnessing mechanical instabilities at the nanoscale to achieve ultra-low stiffness metals

Alloy and microstructure optimization have led to impressive improvements in the strength of engineering metals, while the range of Young's moduli achievable has remained essentially unchanged. This is because stiffness is insensitive to microstructure and bounded by individual components in composites. Here we design ultra-low stiffness in fully dense, nanostructured metals via the stabilization of a mechanically unstable, negative stiffness state of a martensitic alloy by its coherent integration with a compatible, stable second component. Explicit large-scale molecular dynamics simulations of the metamaterials with state of the art potentials confirm the expected ultra-low stiffness while maintaining full strength. We find moduli as low as 2 GPa, a value typical of soft materials and over one order of magnitude lower than either constituent, defying long-standing composite bounds. Such properties are attractive for flexible electronics and implantable devices. Our concept is generally applicable and could significantly enhance materials science design space.

An injectable poly(caprolactone trifumarate-gelatin microparticles) (PCLTF-GMPs) scaffold for irregular bone defects: Physical and mechanical characteristics

Recently, a modified form of a three-dimension (3D) porous poly(caprolactone-trifumarate) (PCLTF) scaffold has been produced using a fabrication technique that involves gelatin microparticles porogen leaching. This poly(caprolactone trifumarate-gelatin microparticles) (PCLTF-GMPs) scaffold has been shown to be biocompatible, more flowable clinically, and has a shorter degradation time as compared to its existing predecessors. In this report, a detailed characterization of this new scaffold was performed by testing its cytocompatibility, analyzing the surface topography, and understanding its thermal, physical and mechanical properties. The result showed that the PCLTF-GMPs has no critical cytotoxic effect. To confirm improvement, the surface properties were compared against the older version of PCLTF fabricated using salt porogen leaching. This PCLTF-GMPs scaffold showed no significant difference (unpaired t-test; p>0.05) in mechanical properties before and after gelatin leaching. However, it is mechanically weaker when compared to its predecessors. It has a high biodegradability rate of 16weeks. The pore size produced ranges from 40 to 300μm, and the RMS roughness is 613.7±236.9nm. These characteristics are condusive for osteoblast in-growth, as observed by the extension of filopodia across the macropores. Overall, this newly produced material has good thermal, physical and mechanical properties that complements its biocompatibility and ease of use.

Microstructure, mechanical properties and superelasticity of biomedical porous NiTi alloy prepared by microwave sintering

Porous NiTi alloys were prepared by microwave sintering using ammonium hydrogen carbonate (NH4HCO3) as the space holder agent to adjust the porosity in the range of 22-62%. The effects of porosities on the microstructure, hardness, compressive strength, bending strength, elastic modulus, phase transformation temperature and superelasticity of the porous NiTi alloys were investigated. The results showed that the porosities and average pore sizes of the porous NiTi alloys increased with increasing the contents of NH4HCO3. The porous NiTi alloys consisted of nearly single NiTi phase, with a very small amount of two secondary phases (Ni3Ti, NiTi2) when the porosities are lower than 50%. The amount of Ni3Ti and NiTi2 phases increased with further increasing of the porosity proportion. The porosities had few effects on the phase transformation temperatures of the porous NiTi alloys. By increasing the porosities, all of the hardness, compressive strength, elastic modulus, bending strength and superelasticity of the porous NiTi alloys decreased. However, the compressive strength and bending strength were higher or close to those of natural bone and the elastic modulus was close to the natural bone. The superelastic recovery strain of the trained porous NiTi alloys could reach between 3.1 and 4.7% at the pre-strain of 5%, even if the porosity was up to 62%. Moreover, partial shape memory effect was observed for all porosity levels under the experiment conditions. Therefore, the microwave sintered porous NiTi alloys could be a promising candidate for bone implant.

Porous NiTi shape memory alloys produced by SHS: microstructure and biocompatibility in comparison with Ti2Ni and TiNi3

Shape memory alloys based on NiTi have found their main applications in manufacturing of new biomedical devices mainly in surgery tools, stents and orthopedics. Porous NiTi can exhibit an engineering elastic modulus comparable to that of cortical bone (12-17 GPa). This condition, combined with proper pore size, allows good osteointegration. Open cells porous NiTi was produced by self propagating high temperature synthesis (SHS), starting from Ni and Ti mixed powders. The main NiTi phase is formed during SHS together with other Ni-Ti compounds. The biocompatibility of such material was investigated by single culture experiment and ionic release on small specimen. In particular, NiTi and porous NiTi were evaluated together with elemental Ti and Ni reference metals and the two intermetallic TiNi3, Ti2Ni phases. This approach permitted to clearly identify the influence of secondary phases in porous NiTi materials and relation with Ni-ion release. The results indicated, apart the well-known high toxicity of Ni, also toxicity of TiNi3, whilst phases with higher Ti content showed high biocompatibility. A slightly reduced biocompatibility of porous NiTi was ascribed to combined effect of TiNi3 presence and topography that requires higher effort for the cells to adapt to the surface.

Metals for bone implants. Part 1. Powder metallurgy and implant rendering

New metal alloys and metal fabrication strategies are likely to benefit future skeletal implant strategies. These metals and fabrication strategies were looked at from the point of view of standard-of-care implants for the mandible. These implants are used as part of the treatment for segmental resection due to oropharyngeal cancer, injury or correction of deformity due to pathology or congenital defect. The focus of this two-part review is the issues associated with the failure of existing mandibular implants that are due to mismatched material properties. Potential directions for future research are also studied. To mitigate these issues, the use of low-stiffness metallic alloys has been highlighted. To this end, the development, processing and biocompatibility of superelastic NiTi as well as resorbable magnesium-based alloys are discussed. Additionally, engineered porosity is reviewed as it can be an effective way of matching the stiffness of an implant with the surrounding tissue. These porosities and the overall geometry of the implant can be optimized for strain transduction and with a tailored stiffness profile. Rendering patient-specific, site-specific, morphology-specific and function-specific implants can now be achieved using these and other metals with bone-like material properties by additive manufacturing. The biocompatibility of implants prepared from superelastic and resorbable alloys is also reviewed.

Development of porous titanium for biomedical applications: A comparison between loose sintering and space-holder techniques

One of the most important concerns in long-term prostheses is bone resorption as a result of the stress shielding due to stiffness mismatch between bone and implant. The aim of this study was to obtain porous titanium with stiffness values similar to that exhibited by cortical bone. Porous samples of commercial pure titanium grade-4 were obtained by following both loose-sintering processing and space-holder technique with NaCl between 40 and 70% in volume fraction. Both mechanical properties and porosity morphology were assessed. Young's modulus was measured using uniaxial compression testing, as well as ultrasound methodology. Complete characterization and mechanical testing results allowed us to determine some important findings: (i) optimal parameters for both processing routes; (ii) better mechanical response was obtained by using space-holder technique; (iii) pore geometry of loose sintering samples becomes more regular with increasing sintering temperature; in the case of the space-holder technique that trend was observed for decreasing volume fraction; (iv) most reliable Young's modulus measurements were achieved by ultrasound technique.

Low elastic modulus titanium-nickel scaffolds for bone implants

The superelastic nature of repeating the human bones is crucial to the ideal artificial biomedical implants to ensure smooth load transfer and foster the ingrowth of new bone tissues. Three dimensional interconnected porous TiNi scaffolds, which have the tailorable porous structures with micro-hole, were fabricated by slurry immersing with polymer sponge and sintering method. The crystallinity and phase composition of scaffolds were studied by X-ray diffraction. The pore morphology, size and distribution in the scaffolds were characterized by scanning electron microscopy. The porosity ranged from 65 to 72%, pore size was 250-500μm. Compressive strength and elastic modulus of the scaffolds were ~73MPa and ~3GPa respectively. The above pore structural and mechanical properties are similar to those of cancellous bone. In the initial cell culture test, osteoblasts adhered well to the scaffold surface during a short time, and then grew smoothly into the interconnected pore channels. These results indicate that the porous TiNi scaffolds fabricated by this method could be bone substitute materials.

A review on nickel-free nitrogen containing austenitic stainless steels for biomedical applications

The field of biomaterials has become a vital area, as these materials can enhance the quality and longevity of human life. Metallic materials are often used as biomaterials to replace structural components of the human body. Stainless steels, cobalt-chromium alloys, commercially pure titanium and its alloys are typical metallic biomaterials that are being used for implant devices. Stainless steels have been widely used as biomaterials because of their very low cost as compared to other metallic materials, good mechanical and corrosion resistant properties and adequate biocompatibility. However, the adverse effects of nickel ions being released into the human body have promoted the development of "nickel-free nitrogen containing austenitic stainless steels" for medical applications. Nitrogen not only replaces nickel for austenitic structure stability but also much improves steel properties. Here we review the harmful effects associated with nickel and emphatically the advantages of nitrogen in stainless steel, as well as the development of nickel-free nitrogen containing stainless steels for medical applications. By combining the benefits of stable austenitic structure, high strength, better corrosion and wear resistance and superior biocompatibility in comparison to the currently used austenitic stainless steel (e.g. 316L), the newly developed nickel-free high nitrogen austenitic stainless steel is a reliable substitute for the conventionally used medical stainless steels.

Fe-Pd based ferromagnetic shape memory actuators for medical applications: Biocompatibility, effect of surface roughness and protein coatings

Ferromagnetic shape memory (FMSM) alloys constitute an exciting new class of smart materials that can yield magnetically switchable strains of several percent at constant temperatures and frequencies from quasi-static up to some kilohertz. In addition to their FMSM properties, these alloys can still be operated as conventional shape memory materials and also exhibit related superelasticity, which are both important features for use in medical devices. In this study, extensive in vitro assessments demonstrate for the first time that vapor-deposited single crystalline Fe(70)Pd(30) thin films and roughness graded polycrystalline splats of the same stoichiometry exhibit excellent biocompatibility and even bioactivity in contact with different cell types-a prerequisite for medical applications. The present study shows that fibroblast and epithelial cell lines, as well as primary osteoblast cells, proliferate well on Fe-Pd. The number of focal contacts, important for strong tissue bonding, can be improved with different binding agents from the extracellular matrix. However, even without coating, there is clear evidence that cells on Fe-Pd substrates behave similarly to control experiments. Additionally, cytotoxic effects of polycrystalline surfaces with various roughness profiles can be excluded, giving another tunable parameter for applying Fe-Pd magnetically switchable membranes in, e.g., stents and valves.

Wear mechanism and tribological characteristics of porous NiTi shape memory alloy for bone scaffold

The abraded debris might cause osteocytic osteolysis on the interface between implants and bone tissues, thus inducing the subsequent mobilization of implants gradually and finally resulting in the failure of bone implants, which imposes restrictions on the applications of porous NiTi shape memory alloys (SMAs) scaffolds for bone tissue engineering. In this work, the effects of the annealing temperature, applied load, and porosity on the tribological behavior and wear resistance of three-dimensional porous NiTi SMA are investigated systematically. The porous structure and phase transformation during the exothermic process affect the tribological properties and wear mechanism significantly. In general, a larger porosity leads to better tribological resistance but sometimes, SMAs with small porosity possess better wear resistance than ones with higher porosity during the initial sliding stage. It can be ascribed to the better superelasticity of the former at the test temperature. The porous NiTi phase during the exothermic reaction also plays an important role in the wear resistance. Generally, porous NiTi has smaller friction coefficients under high loads due to stress-induced superelasticity. The wear mechanism is discussed based on plastic deformation and microcrack propagation.

Shape-memory NiTi with two-dimensional networks of micro-channels

A process was developed for fabricating arrays of micro-channels in shape-memory NiTi for bone implant applications, with a tailorable internal architecture expected to improve biomechanical compatibility and osseointegration. Ni-51.4 at.% Ti with 24-34 vol.% porosity was fabricated by electrochemical dissolution of parallel layers of steel wire meshes embedded within a NiTi matrix during hot pressing of NiTi powders. The resulting NiTi structures exhibit parallel layers of orthogonally interconnected micro-channels with 350-400 μm diameters that exactly replicate the steel meshes. When low-carbon steel wires are used, iron diffuses into the surrounding NiTi during the densification step, creating a Fe-enriched zone near the wires. For high-carbon steel wires, TiC forms at the steel/NiTi interface and inhibits iron diffusion but also depletes some titanium from the adjacent NiTi. In both cases, the NiTi regions near the micro-channels exhibit altered phase transformation characteristics. These NiTi structures with replicated networks of micro-channels have excellent potential as bone implants and scaffolds given: (i) the versatility in channel size, shape, fraction and spatial arrangement; (ii) their low stiffness (15-26 GPa), close to 12-17 GPa for cortical bone; (iii) their high compressive strength (420-600 MPa at 8-9% strain); and (iv) their excellent compressive strain recovery (91-94% of an applied strain of 6%) by a combination of elasticity, superelasticity and the shape-memory effect.

Hydrogen release from titanium hydride in foaming of orthopedic NiTi scaffolds

Titanium hydride powders are utilized to enhance the foaming process in the formation of orthopedic NiTi scaffolds during capsule-free hot isostatic pressing. In order to study the formation mechanism, the thermal behavior of titanium hydride and hydrogen release during the heating process are systematically investigated in air and argon and under vacuum by X-ray diffraction (XRD), thermal analysis, including thermogravimetric analysis and differential scanning calorimetry, energy dispersive X-ray spectroscopy, and transmission electron microscopy. Our experiments reveal that hydrogen is continuously released from titanium hydride as the temperature is gradually increased from 300 to 700 °C. Hydrogen is released in two transitions: TiH1.924→TiH1.5/TiH1.7 between 300 °C and 400 °C and TiH1.5/TiH1.7→α-Ti between 400 °C and 600 °C. In the lower temperature range between 300 °C and 550 °C the rate of hydrogen release is slow, but the decomposition rate increases sharply above 550 °C. The XRD patterns obtained in air and under vacuum indicate that the surface oxide layer can deter hydrogen release. The pressure change is monitored in real time and the amount of hydrogen released is affected by the processing temperature and holding time. Holding processes at 425 °C, 480 °C, 500 °C, 550 °C, and 600 °C are found to significantly improve the porous structure in the NiTi scaffolds due to the stepwise release of hydrogen. NiTi scaffolds foamed by stepwise release of hydrogen are conducive to the attachment and proliferation of osteoblasts and the resulting pore size also favor in-growth of cells.

Application of laser engineered net shaping (LENS) to manufacture porous and functionally graded structures for load bearing implants

Fabrication of net shape load bearing implants with complex anatomical shapes to meet desired mechanical and biological performance is still a challenge. In this article, an overview of our research activities is discussed focusing on application of Laser Engineered Net Shaping (LENS) toward load bearing implants to increase in vivo life time. We have demonstrated that LENS can fabricate net shape, complex metallic implants with designed porosities up to 70 vol.% to reduce stress-shielding. The effective modulus of Ti, NiTi, and other alloys was tailored to suit the modulus of human cortical bone by introducing 12-42 vol.% porosity. In addition, laser processed porous NiTi alloy samples show a 2-4% recoverable strain, a potentially significant result for load bearing implants. To minimize the wear induced osteolysis, unitized structures with functionally graded Co-Cr-Mo coating on porous Ti6Al4V were also made using LENS, which showed high hardness with excellent bone cell-materials interactions. Finally, LENS is also being used to fabricate porous, net shape implants with a functional gradation in porosity characteristics.

Metallic Scaffolds for Bone Regeneration

Bone tissue engineering is an emerging interdisciplinary field in Science, combining expertise in medicine, material science and biomechanics. Hard tissue engineering research is focused mainly in two areas, osteo and dental clinical applications. There is a lot of exciting research being performed worldwide in developing novel scaffolds for tissue engineering. Although, nowadays the majority of the research effort is in the development of scaffolds for non-load bearing applications, primarily using soft natural or synthetic polymers or natural scaffolds for soft tissue engineering; metallic scaffolds aimed for hard tissue engineering have been also the subject of in vitro and in vivo research and industrial development. In this article, descriptions of the different manufacturing technologies available to fabricate metallic scaffolds and a compilation of the reported biocompatibility of the currently developed metallic scaffolds have been performed. Finally, we highlight the positive aspects and the remaining problems that will drive future research in metallic constructs aimed for the reconstruction and repair of bone.

Titanium foam-bioactive nanofiber hybrids for bone regeneration

We have reported previously a method to introduce bioactive nanofiber networks through self-assembly into the pores of titanium alloy foams for bone repair. In this study we evaluate the in vitro colonization by mouse pre-osteoblastic cells of these metal-peptide amphiphile hybrids containing phosphoserine residues and the RGDS epitope. The aim was to determine the effect of varying the RGDS epitope concentration within a given range, and confirm the ability for cells to infiltrate and survive within the nanofiber-filled interconnected porosity of the hybrid material. We performed proliferation (DNA content) and differentiation assays (alkaline phosphatase and osteopontin expression) as well as SEM and confocal microscopy to evaluate cell colonization of the hybrids. At the RGDS epitope concentrations used in the nanofiber networks, all samples demonstrated significant cell migration into the hybrids, proliferation, and differentiation into osteoblastic lineage.