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Bandyopadhyay A, Mitra I, Ciliveri S, Avila JD, Dernell W, Goodman SB, Bose S. Additively manufactured Ti-Ta-Cu alloys for the next-generation load-bearing implants. INTERNATIONAL JOURNAL OF EXTREME MANUFACTURING 2024; 6:015503. [PMID: 38021398 PMCID: PMC10654690 DOI: 10.1088/2631-7990/ad07e7] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 08/04/2023] [Revised: 09/19/2023] [Accepted: 10/30/2023] [Indexed: 12/01/2023]
Abstract
Bacterial colonization of orthopedic implants is one of the leading causes of failure and clinical complexities for load-bearing metallic implants. Topical or systemic administration of antibiotics may not offer the most efficient defense against colonization, especially in the case of secondary infection, leading to surgical removal of implants and in some cases even limbs. In this study, laser powder bed fusion was implemented to fabricate Ti3Al2V alloy by a 1:1 weight mixture of CpTi and Ti6Al4V powders. Ti-Tantalum (Ta)-Copper (Cu) alloys were further analyzed by the addition of Ta and Cu into the Ti3Al2V custom alloy. The biological, mechanical, and tribo-biocorrosion properties of Ti3Al2V alloy were evaluated. A 10 wt.% Ta (10Ta) and 3 wt.% Cu (3Cu) were added to the Ti3Al2V alloy to enhance biocompatibility and impart inherent bacterial resistance. Additively manufactured implants were investigated for resistance against Pseudomonas aeruginosa and Staphylococcus aureus strains of bacteria for up to 48 h. A 3 wt.% Cu addition to Ti3Al2V displayed improved antibacterial efficacy, i.e. 78%-86% with respect to CpTi. Mechanical properties for Ti3Al2V-10Ta-3Cu alloy were evaluated, demonstrating excellent fatigue resistance, exceptional shear strength, and improved tribological and tribo-biocorrosion characteristics when compared to Ti6Al4V. In vivo studies using a rat distal femur model revealed improved early-stage osseointegration for alloys with 10 wt.% Ta addition compared to CpTi and Ti6Al4V. The 3 wt.% Cu-added compositions displayed biocompatibility and no adverse inflammatory response in vivo. Our results establish the Ti3Al2V-10Ta-3Cu alloy's synergistic effect on improving both in vivo biocompatibility and microbial resistance for the next generation of load-bearing metallic implants.
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Affiliation(s)
- Amit Bandyopadhyay
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, United States of America
| | - Indranath Mitra
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, United States of America
| | - Sushant Ciliveri
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, United States of America
| | - Jose D Avila
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, United States of America
| | - William Dernell
- Veterinary Clinical Sciences, College of Veterinary Medicine, Washington State University, Pullman, WA 99164, United States of America
| | - Stuart B Goodman
- Department of Orthopedic Surgery, Stanford University Medical Center, Redwood City, CA 94063, United States of America
| | - Susmita Bose
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, United States of America
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Ciliveri S, Bandyopadhyay A. Additively Manufactured SiO 2 and Cu-Added Ti Implants for Synergistic Enhancement of Bone Formation and Antibacterial Efficacy. ACS APPLIED MATERIALS & INTERFACES 2024; 16:3106-3115. [PMID: 38214659 DOI: 10.1021/acsami.3c14994] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/13/2024]
Abstract
Commercially pure titanium (CpTi), a bioinert metal, is used as an implant material at low load-bearing sites and as a porous coating on Ti6Al4V at high load-bearing sites. There is an unmet need for metallic biomaterials to improve osseointegration and inherent antimicrobial resistance. In this study, we have added 1 wt % SiO2 and 3 wt % Cu to the CpTi matrix and processed via metal additive manufacturing (AM). Si4+ ions promote angiogenesis and osteogenesis. CpTi-SiO2 composition exhibited 4.5 times higher bone formation at the bone-implant interface over CpTi in an in vivo study with a rat distal femur model. In vitro bacterial studies with Gram-positive Staphylococcus aureus bacterium revealed 85% antibacterial efficacy by CpTi-SiO2-3Cu than CpTi. CpTi-SiO2-3Cu did not show any inflammatory markers in vivo, indicating the absence of cytotoxicity, but displayed delayed osseointegration compared to CpTi-SiO2. CpTi-SiO2-3Cu displayed 3-fold higher mineralized bone formation than CpTi. Our results emphasize the synergistic effect of SiO2 and Cu addition in CpTi, promoting enhanced early stage osseointegration and inherent antibacterial efficacy, contributing toward implant longevity and stability in vivo.
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Affiliation(s)
- Sushant Ciliveri
- W. M. Keck Biomedical Materials Research Laboratory School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
| | - Amit Bandyopadhyay
- W. M. Keck Biomedical Materials Research Laboratory School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, United States
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Ciliveri S, Bandyopadhyay A. Enhanced osteogenesis and bactericidal performance with additively manufactured MgO and Cu-added CpTi for load-bearing implants. Int J Bioprint 2023; 9:1167. [PMID: 38116397 PMCID: PMC10730012 DOI: 10.36922/ijb.1167] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/21/2023] Open
Abstract
Titanium, being the ultimate choice of metallic material for implant applications, its bio-inertness causes delayed bone-tissue integration at the implant site and prevents expedited healing for the patient. This can cause a severe issue for patients with immunocompromised bone health. Infections at the implant site are another concern; titanium does not offer inherent antimicrobial properties. Current strategies addressing the issues above include using cemented implants as a coating on Ti6Al4V bulk material for orthopedic applications. Roadblock arises with coating failure due to weak interfacial bond at the Ti-cement interface, resulting in revision surgeries. We have added osteogenic MgO and antibacterial Cu to CpTi and processed them using metal additive manufacturing (AM) to address these issues. Mg, an essential trace element in the body, has been proven to enhance osseointegration in vivo. Cu has been popular for its bactericidal capabilities. With 1 wt.% of MgO addition in the CpTi matrix, we have observed a four-fold increase in the mineralized bone formation at the bone-implant interface in vivo. The presence of 3 wt.% of Cu showed no cytotoxicity markers, and adding Cu to CpTi-MgO chemical makeup showed similar in vivo performance to CpTi-MgO. In vitro bacterial studies with gram-positive Staphylococcus aureus bacteria showed 81% bacterial efficiency displayed by CpTi-MgO-Cu at the end of 72 h of culture. Our findings highlight the synergistic benefits of CpTi-MgO-Cu, which exhibit superior early-stage osseointegration and antimicrobial capabilities.
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Affiliation(s)
- Sushant Ciliveri
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, USA
| | - Amit Bandyopadhyay
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, USA
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Bandyopadhyay A, Ciliveri S, Guariento S, Zuckschwerdt N, Hogg WW. Fatigue behavior of additively manufactured Ti3Al2V alloy. MATERIALS SCIENCE IN ADDITIVE MANUFACTURING 2023; 2:1705. [PMID: 38174053 PMCID: PMC10762691 DOI: 10.36922/msam.1705] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/05/2024]
Abstract
This study measured the tensile, compression, and fatigue behavior of additively manufactured Ti3Al2V as a function of build orientation. Ti3Al2V alloy was prepared by mixing commercially pure titanium (CpTi) and Ti6Al4V in 1:1 wt. ratio. Laser powder bed fusion (L-PBF) based additive manufacturing (AM) technique was used to fabricate the samples. Tensile tests resulted in an ultimate strength of 989 ± 8 MPa for Ti3Al2V. Ti6Al4V 90° orientation samples showed a compressive yield strength of 1178 ± 33 MPa, and that for Ti3Al2V 90° orientation was 968 ± 24 MPa. Varying the build orientation to account for anisotropy, Ti32-45° and Ti32-0° displayed similar compressive yield strength values of 1071 ± 16 and 1051± 18 MPa, respectively, higher than Ti32-90°. Fatigue loading revealed an endurance limit (10 million cycles) of 250 MPa for Ti6Al4V and 219 MPa for Ti3Al2V built at 90° orientations. The effect of the build orientation was significant under fatigue loading; Ti3Al2V built at 45° displayed an endurance limit of 387.5 MPa, and 0° showed 512 MPa; more than two-fold increment in endurance limit was observed. Our results show the potential of Ti3Al2V alloy for orthopedic devices, replacing Ti6Al4V alloy, particularly in load-bearing applications.
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Affiliation(s)
- Amit Bandyopadhyay
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, USA
| | - Sushant Ciliveri
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, USA
| | - Stefano Guariento
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, USA
| | - Nathan Zuckschwerdt
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, USA
| | - William W Hogg
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, USA
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Bandyopadhyay A, Mitra I, Avila JD, Upadhyayula M, Bose S. Porous metal implants: processing, properties, and challenges. INTERNATIONAL JOURNAL OF EXTREME MANUFACTURING 2023; 5:032014. [PMID: 37476350 PMCID: PMC10355163 DOI: 10.1088/2631-7990/acdd35] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 12/23/2022] [Revised: 03/26/2023] [Accepted: 06/09/2023] [Indexed: 07/22/2023]
Abstract
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.
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Affiliation(s)
- Amit Bandyopadhyay
- W. M. Keck Biomedical Materials Research Lab, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, United States of America
| | - Indranath Mitra
- W. M. Keck Biomedical Materials Research Lab, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, United States of America
| | - Jose D Avila
- W. M. Keck Biomedical Materials Research Lab, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, United States of America
| | - Mahadev Upadhyayula
- W. M. Keck Biomedical Materials Research Lab, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, United States of America
| | - Susmita Bose
- W. M. Keck Biomedical Materials Research Lab, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164, United States of America
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Ciliveri S, Bandyopadhyay A. Understanding the influence of alloying elements on the print quality of powder bed fusion-based metal additive manufacturing: Ta and Cu addition to Ti alloy. VIRTUAL AND PHYSICAL PROTOTYPING 2023; 18:e2248464. [PMID: 38911127 PMCID: PMC11192459 DOI: 10.1080/17452759.2023.2248464] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/28/2023] [Accepted: 08/02/2023] [Indexed: 06/25/2024]
Abstract
Alloy design coupled with metal additive manufacturing (AM) opens many opportunities for materials innovation. Investigating the effect of printing parameters for alloy design is essential to achieve good part quality. Among different factors, laser absorptivity, heat diffusivity, and in situ intermetallic phase formations are critical. In this study, the first step employed was a reduction in Al and V contents in Ti6Al4V to design Ti3Al2V alloy, and further 10 wt.% tantalum (Ta) and 3 wt.% copper (Cu) were added to Ti3Al2V. A synergistic effect of Ta and Cu addition in Ti3Al2V negated their effect with higher porosities in Ti3Al2V-Ta-Cu. Ti3Al2V-Ta composition was more sensitive to the laser power, whereas Ti3Al2V-Ta-Cu to the overall energy density. Understanding the effect of energy density on these alloys' microstructural evolution and mechanical properties highlights the need for process-property optimization during alloy design using AM.
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Affiliation(s)
- Sushant Ciliveri
- W. M. Keck Biomedical Materials Research Lab, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164-2920, USA
| | - Amit Bandyopadhyay
- W. M. Keck Biomedical Materials Research Lab, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164-2920, USA
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Bandyopadhyay A, Mitra I, Goodman SB, Kumar M, Bose S. Improving Biocompatibility for Next Generation of Metallic Implants. PROGRESS IN MATERIALS SCIENCE 2023; 133:101053. [PMID: 36686623 PMCID: PMC9851385 DOI: 10.1016/j.pmatsci.2022.101053] [Citation(s) in RCA: 19] [Impact Index Per Article: 19.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/01/2023]
Abstract
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.
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Affiliation(s)
- Amit Bandyopadhyay
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164-2920
| | - Indranath Mitra
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164-2920
| | - Stuart B. Goodman
- Department of Orthopedic Surgery, Stanford University Medical Center, Redwood City, CA 94063
| | | | - Susmita Bose
- W. M. Keck Biomedical Materials Research Laboratory, School of Mechanical and Materials Engineering, Washington State University, Pullman, WA 99164-2920
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