3D-additive deposition of an antibacterial and osteogenic silicon nitride coating on orthopaedic titanium substrate

Evaluation of tribological and biological properties of Ti6Al4V coated with Si3N4/ND nanoparticles for orthopedic applications: a comprehensive analysis

In this study, the biocompatibility and tribological properties of Ti6Al4V coated with silicon nitride (Si3N4)/nanodiamond using the electrophoretic deposition method were investigated. Suspensions of various aqueous and alcoholic solutions were prepared in the presence of CTAB and SDS dispersers. The most stable suspension system for the electrophoresis process was selected (aqueous media/ SDS disperser). Four different voltages (20, 30, 40 and 50 V) were applied to study the effect of voltage on the coating property. One could find that processing with 40 V obtained the best coating. The nano-composite coating was characterized using scanning electron microscopy equipped with energy dispersive spectroscopy, mapping analysis and x-ray diffraction after the coating process. The samples were then subjected to two nanoindentation and nano-scratching tests to evaluate their tribological properties. Biocompatibility was assessed in an ex vivo environment using two cell culture tests to evaluate survival and cellular adhesion. The results showed that the hardness and modulus elasticity of the coated sample increased from 85 to 124 GPa and 1.14-3.55 GPa, respectively, compared to the non-coated sample. Additionally, the MTT test results indicated that cellular survival and proliferation of MG63 cells increased from 86% for the non-coated sample to 92% for the Ti6Al4V/Si3N4/ND sample. These findings have implications for orthopedic implant applications.

Investigation on the Osteogenic and Antibacterial Properties of Silicon Nitride-Coated Titanium Dental Implants

The silicon nitride (Si3N4) coating exhibits promising potential in oral applications due to its excellent osteogenic and antibacterial properties. However, a comprehensive investigation of Si3N4 coatings in the context of dental implants is still lacking, especially regarding their corrosion resistance and in vivo performance. In this study, Si3N4 coatings were prepared on a titanium surface using the nonequilibrium magnetron sputtering method. A systematic comparison among the titanium group (Ti), Si3N4 coating group (Si3N4-Ti), and sandblasted and acid-etched-treated titanium group (SLA-Ti) has been conducted in vitro and in vivo. The results showed that the Si3N4-Ti group had the best corrosion resistance and antibacterial properties, which were mainly attributed to the dense structure and chemical activity of Si-O and Si-N bonds on the surface. Furthermore, the Si3N4-Ti group exhibited superior cellular responses in vitro and new bone regeneration and osseointegration in vivo, respectively. In this sense, silicon nitride coating shows promising prospects in the field of dental implantology.

3D printed silicon nitride, alumina, and hydroxyapatite ceramic reinforced Ti6Al4V composites - Tailored microstructures to enhance bio-tribo-corrosion and antibacterial properties

This study utilized directed energy deposition (DED) as a metal additive manufacturing (AM) technique to create ceramic-reinforced composites of Ti6Al4V (Ti64) with hydroxyapatite (HA), alumina (Al2O3), and silicon nitride (Si3N4). The resulting composites had tailored microstructures designed to improve bio-tribological and antibacterial properties simultaneously. A total of 5-wt % ceramic reinforcement were used in Ti64 in four different composites - (1) only Si3N4 (5S), (2) only Al2O3 (5A), (3) 3 wt % Si3N4 and 2 wt% HA (32SH) and (4) 3 wt % Al2O3 and 2 wt% HA (32AH). Microstructural observations revealed that martensite transformation between α and β-Ti in composites resulted in compressive residual stress at the matrix. Coherency is observed between the ceramic particles and Ti64 matrix, preventing cracking, debonding, or porosity. Vicker's hardness of the composite samples increases by 50% over the Ti64 matrix. Various strengthening mechanisms are discussed in detail, representing the reason behind the reduction of compound wear in 5S and 5A composites. Si3N4-added composites demonstrated an antibacterial response against gram-positive Staphylococcus aureus. The multifunctional performance of ceramic-reinforced Ti64 composites makes them suitable for articulating biomedical devices such as femoral heads in hip implants.

A biocompatible silicon nitride dental implant material prepared by digital light processing technology

For decades, titanium has been the preferred material for dental implant fabrication. However, metallic ions and particles can cause hypersensitivity and aseptic loosening. The growing demand for metal-free dental restorations has also promoted the development of ceramic-based dental implants, such as silicon nitride. In this study, silicon nitride (Si₃N₄) dental implants were fabricated for biological engineering by photosensitive resin based digital light processing (DLP) technology, comparable to conventionally produced Si₃N₄ ceramics. The flexural strength was (770 ± 35) MPa by the three-point bending method, and the fracture toughness was (13.3 ± 1.1) MPa · m^1/2 by the unilateral pre-cracked beam method. The elastic modulus measured by the bending method was (236 ± 10) GPa. To confirm whether the prepared Si₃N₄ ceramics possessed good biocompatibility, in vitro biological experiments were performed with the fibroblast cell line L-929, and preferable cell proliferation and apoptosis were observed at the initial stages. Hemolysis test, oral mucous membrane irritation test, and acute systemic toxicity test (oral route) further confirmed that the Si₃N₄ ceramics did not exhibit hemolysis reaction, oral mucosal stimulation, or systemic toxicity. The findings indicate that Si₃N₄ dental implant restorations with personalized structures prepared by DLP technology have good mechanical properties and biocompatibility, which has great application potential in the future.

Advanced Surface Modification for 3D-Printed Titanium Alloy Implant Interface Functionalization

With the development of three-dimensional (3D) printed technology, 3D printed alloy implants, especially titanium alloy, play a critical role in biomedical fields such as orthopedics and dentistry. However, untreated titanium alloy implants always possess a bioinert surface that prevents the interface osseointegration, which is necessary to perform surface modification to enhance its biological functions. In this article, we discuss the principles and processes of chemical, physical, and biological surface modification technologies on 3D printed titanium alloy implants in detail. Furthermore, the challenges on antibacterial, osteogenesis, and mechanical properties of 3D-printed titanium alloy implants by surface modification are summarized. Future research studies, including the combination of multiple modification technologies or the coordination of the structure and composition of the composite coating are also present. This review provides leading-edge functionalization strategies of the 3D printed titanium alloy implants.

3D Printed Cobalt-Chromium-Molybdenum Porous Superalloy with Superior Antiviral Activity

COVID-19 pandemic and associated supply-chain disruptions emphasise the requirement for antimicrobial materials for on-demand manufacturing. Besides aerosol transmission, SARS-CoV-2 is also propagated through contact with virus-contaminated surfaces. As such, the development of effective biofunctional materials that can inactivate SARS-CoV-2 is critical for pandemic preparedness. Such materials will enable the rational development of antiviral devices with prolonged serviceability, reducing the environmental burden of disposable alternatives. This research reveals the novel use of Laser Powder Bed Fusion (LPBF) to 3D print porous Cobalt-Chromium-Molybdenum (Co-Cr-Mo) superalloy with potent antiviral activity (100% viral inactivation in 30 min). The porous material was rationally conceived using a multi-objective surrogate model featuring track thickness (tt) and pore diameter (ϕd) as responses. The regression analysis found the most significant parameters for Co-Cr-Mo track formation to be the interaction effects of scanning rate (Vs) and laser power (Pl) in the order PlVs>Vs>Pl. Contrastively, the pore diameter was found to be primarily driven by the hatch spacing (Sh). The study is the first to demonstrate the superior antiviral properties of 3D printed Co-Cr-Mo superalloy against an enveloped virus used as biosafe viral model of SARS-CoV-2. The material significantly outperforms the viral inactivation time of other broadly used antiviral metals such as copper and silver, as the material's viral inactivation time was from 5 h to 30 min. As such, the study goes beyond the current state-of-the-art in antiviral alloys to provide extra protection to combat the SARS-CoV-2 viral spread. The evolving nature of the COVID-19 pandemic brings new and unpredictable challenges where on-demand 3D printing of antiviral materials can achieve rapid solutions while reducing the environmental impact of disposable devices.

Embracing Additive Manufacturing Technology through Fused Filament Fabrication for Antimicrobial with Enhanced Formulated Materials

Antimicrobial materials produced by 3D Printing technology are very beneficial, especially for biomedical applications. Antimicrobial surfaces specifically with enhanced antibacterial property have been prepared using several quaternary salt-based agents, such as quaternary ammonium salts and metallic nanoparticles (NPs), such as copper and zinc, which are incorporated into a polymeric matrix mainly through copolymerization grafting and ionic exchange. This review compared different materials for their effectiveness in providing antimicrobial properties on surfaces. This study will help researchers choose the most suitable method of developing antimicrobial surfaces with the highest efficiency, which can be applied to develop products compatible with 3D Printing Technology.

Multifunctional natural polymer-based metallic implant surface modifications

High energy traumas could cause critical damage to bone, which will require permanent implants to recover while functionally integrating with the host bone. Critical sized bone defects necessitate the use of bioactive metallic implants. Because of bioinertness, various methods involving surface modifications such as surface treatments, the development of novel alloys, bioceramic/bioglass coatings, and biofunctional molecule grafting have been utilized to effectively integrate metallic implants with a living bone. However, the applications of these methods demonstrated a need for an interphase layer improving bone-making to overcome two major risk factors: aseptic loosening and peri-implantitis. To accomplish a biologically functional bridge with the host to prevent loosening, regenerative cues, osteoimmunomodulatory modifications, and electrochemically resistant layers against corrosion appeared as imperative reinforcements. In addition, interphases carrying antibacterial cargo were proven to be successful against peri-implantitis. In the literature, metallic implant coatings employing natural polymers as the main matrix were presented as bioactive interphases, enabling rapid, robust, and functional osseointegration with the host bone. However, a comprehensive review of natural polymer coatings, bridging and grafting on metallic implants, and their activities has not been reported. In this review, state-of-the-art studies on multifunctional natural polymer-based implant coatings effectively utilized as a bone tissue engineering (BTE) modality are depicted. Protein-based, polysaccharide-based coatings and their combinations to achieve better osseointegration via the formation of an extracellular matrix-like (ECM-like) interphase with gap filling and corrosion resistance abilities are discussed in detail. The hypotheses and results of these studies are examined and criticized, and the potential future prospects of multifunctional coatings are also proposed as final remarks.

Silicon nitride: a potent solid-state bioceramic inactivator of ssRNA viruses

Surface inactivation of human microbial pathogens has a long history. The Smith Papyrus (2600 ~ 2200 B.C.) described the use of copper surfaces to sterilize chest wounds and drinking water. Brass and bronze on doorknobs can discourage microbial spread in hospitals, and metal-base surface coatings are used in hygiene-sensitive environments, both as inactivators and modulators of cellular immunity. A limitation of these approaches is that the reactive oxygen radicals (ROS) generated at metal surfaces also damage human cells by oxidizing their proteins and lipids. Silicon nitride (Si₃N₄) is a non-oxide ceramic compound with known surface bacterial resistance. We show here that off-stoichiometric reactions at Si₃N₄ surfaces are also capable of inactivating different types of single-stranded RNA (ssRNA) viruses independent of whether their structure presents an envelop or not. The antiviral property of Si₃N₄ derives from a hydrolysis reaction at its surface and the subsequent formation of reactive nitrogen species (RNS) in doses that could be metabolized by mammalian cells but are lethal to pathogens. Real-time reverse transcription (RT)-polymerase chain reaction (PCR) tests of viral RNA and in situ Raman spectroscopy suggested that the products of Si₃N₄ hydrolysis directly react with viral proteins and RNA. Si₃N₄ may have a role in controlling human epidemics related to ssRNA mutant viruses.

Application of Spectroscopy in Additive Manufacturing

Additive manufacturing (AM) is a rapidly expanding material production technique that brings new opportunities in various fields as it enables fast and low-cost prototyping as well as easy customisation. However, it is still hindered by raw material selection, processing defects and final product assessment/adjustment in pre-, in- and post-processing stages. Spectroscopic techniques offer suitable inspection, diagnosis and product trouble-shooting at each stage of AM processing. This review outlines the limitations in AM processes and the prospective role of spectroscopy in addressing these challenges. An overview on the principles and applications of AM techniques is presented, followed by the principles of spectroscopic techniques involved in AM and their applications in assessing additively manufactured parts.

Surface Functionalization of Polyethylene by Silicon Nitride Laser Cladding

Functional coatings are commonly applied to biomaterials in order to improve their properties. In this work, polyethylene was coated with a silicon nitride (Si3N4) powder using a pulsed laser source in a nitrogen gas atmosphere. Several analytical techniques were used to characterize the functionalized surface of the polymer, including Raman spectroscopy, laser microscopy, scanning electron microscopy (SEM), and energy dispersive X-ray spectroscopy (EDS). Antibacterial properties were tested in vitro against Staphylococcus epidermidis. The Si3N4 coating sensibly reduced the amount of living bacteria when compared to the uncoated polymer. Osteoconductivity was also tested in vitro using SaOS-2 osteosarcoma cells. The presence of Si3N4 coating resulted in an increased amount of hydroxyapatite. Coating of polyethylene with silicon nitride may lead to improved performance of indwelling orthopaedic or less invasive medical devices.

Impedance testing of porous Si3N4 scaffolds for skeletal implant applications

Si3N4 ceramics show excellent characteristics of mechanical and chemical resistance in combination with good biocompatibility, antibacterial property and radiolucency. Therefore, they are intensively studied as structural materials in skeletal implant applications. Despite their attractive properties, there are limited data in the field about in vitro studies of cellular growth on ceramic implant materials. In this study, the growth of bone cells was investigated on porous silicon nitride (Si3N4) ceramic implant by using electrochemical impedance spectroscopy (EIS). Partial sintering was performed at 1700 °C with limited amount of sintering additive for the production of porous Si3N4 scaffolds. All samples were then sterilized by using ethylene oxide followed by culturing MG-63 osteosarcoma cells on the substrates for in vitro assays. At 20 and 36 h, EIS was performed and results demonstrated that magnitude of the impedance as a result of the changes in the culture medium increased after incubation with osteosarcoma cells. The changes are attributed to the cellular uptake of charged molecules from the medium. Si3N4 samples appear to show large impedance magnitude changes, especially between 100 and 1 Hz. Impedance changes were also correlated with WST-1 measurements (36 h) and DAPI results.