Compressive behaviour of gyroid lattice structures for human cancellous bone implant applications

Implant Strength Contributes to the Osseointegration Strength of Porous Metallic Materials

Creating the optimal environment for effective and long term osseointegration is a heavily researched and sought-after design criteria for orthopedic implants. A validated multimaterial finite element (FE) model was developed to replicate and understand the results of an experimental in vivo push-out osseointegration model. The FE model results closely predicted global force (at 0.5 mm) and stiffness for the 50-90% porous implants with an r2 of 0.97 and 0.98, respectively. In addition, the FE global force at 0.5 mm showed a correlation to the maximum experimental forces with an r2 of 0.90. The highest porosity implants (80-90%) showed lower stiffnesses and more equitable load sharing but also failed at lower a global force level than the low porosity implants (50-70%). The lower strength of the high porosity implants caused premature plastic deformation of the implant itself during loading as well as significant deformations in the ingrown and surrounding bone, resulting in lower overall osseointegration strength, consistent with experimental measurements. The lower porosity implants showed a balance of sufficient bony ingrowth to support osseointegration strength coupled with implant mechanical properties to circumvent significant implant plasticity and collapse under the loading conditions. Together, the experimental and finite element modeling results support an optimal porosity in the range of 60-70% for maximizing osseointegration with current structure and loading.

Collective Spin-Wave Dynamics in Gyroid Ferromagnetic Nanostructures

Expanding upon the burgeoning discipline of magnonics, this research elucidates the intricate dynamics of spin waves (SWs) within three-dimensional nanoenvironments. It marks a shift from traditionally used planar systems to exploration of magnetization configurations and the resulting dynamics within 3D nanostructures. This study deploys micromagnetic simulations alongside ferromagnetic resonance measurements to scrutinize magnetic gyroids, periodic chiral configurations composed of chiral triple junctions with a period in nanoscale. Our findings uncover distinctive attributes intrinsic to the gyroid network, most notably the localization of collective SW excitations and the sensitivity of the gyroid's ferromagnetic response to the orientation of the static magnetic field, a correlation closely tied to the crystallographic alignment of the structure. Furthermore, we show that for the ferromagnetic resonance, multidomain gyroid films can be treated as a magnonic material with effective magnetization scaled by its filling factor. The implications of our research carry the potential for practical uses such as an effective, metamaterial-like substitute for ferromagnetic parts and lay the groundwork for radio frequency filters. The growing areas of 3D magnonics and spintronics present exciting opportunities to investigate and utilize gyroid nanostructures for signal processing purposes.

Biomimetic dental implant production using selective laser powder bed fusion melting: In-vitro results

Instead of a textured surface with irregular pore size and distribution as in conventional dental implants, the use of lattice structures with regular geometric structure and controlled pore size produced by selective laser powder bed fusion melting (LPDF) technique will provide more predictable and successful results regarding osseointegration and mechanics. In this study, biomimetic dental implants with 2 different pore designs were fabricated by LPDF technique and compared with conventional dental implants in terms of surface characterization and resistance to biomechanical forces. Finite element analysis, scanning electron microscopy, computed micro tomography scanning, ISO 14801 tests and detork tests were used for the comparison. The tested biomimetic implants were found to be as durable as conventional implants in terms of mechanical strength and detork values. They were also found to be 40-60% more advantageous than conventional dental implants with respect to surface area and volume. As a result, it was concluded that biomimetic dental implants with sufficient mechanical strength and complex surface geometries can be made as designed without changing the reliable base material and can be produced using a different manufacturing method.

Effect of Porosity and Pore Shape on the Mechanical and Biological Properties of Additively Manufactured Bone Scaffolds

This study investigates the effect of porosity and pore shape on the biological and mechanical behavior of additively manufactured scaffolds for bone tissue engineering (BTE). Polylactic acid scaffolds with varying porosity levels (15-78%) and pore shapes, including regular (rectangular pores), gyroid, and diamond (triply periodic minimal surfaces) structures, are fabricated by fused filament fabrication. Murine-derived macrophages and human bone marrow-derived mesenchymal stromal cells (hBMSCs) are seeded onto the scaffolds. The compressive behavior and surface morphology of the scaffolds are characterized. The results show that scaffolds with 15%, 30%, and 45% porosity display the highest rate of macrophage and hBMSC growth. Gyroid and diamond scaffolds exhibit a higher rate of macrophage proliferation, while diamond scaffolds exhibit a higher rate of hBMSC proliferation. Additionally, gyroid and diamond scaffolds exhibit better compressive behavior compared to regular scaffolds. Of particular note, diamond scaffolds have the highest compressive modulus and strength. Surface morphology characterization indicates that the surface roughness of diamond and gyroid scaffolds is greater than that of regular scaffolds at the same porosity level, which is beneficial for cell attachment and proliferation. This study provides valuable insights into porosity and pore shape selection for additively manufactured scaffolds in BTE.

Direct Integration of 3D Printing and Cryogel Scaffolds for Bone Tissue Engineering

Cryogels, known for their biocompatibility and porous structure, lack mechanical strength, while 3D-printed scaffolds have excellent mechanical properties but limited porosity resolution. By combining a 3D-printed plastic gyroid lattice scaffold with a chitosan-gelatin cryogel scaffold, a scaffold can be created that balances the advantages of both fabrication methods. This study compared the pore diameter, swelling potential, mechanical characteristics, and cellular infiltration capability of combined scaffolds and control cryogels. The incorporation of the 3D-printed lattice demonstrated patient-specific geometry capabilities and significantly improved mechanical strength compared to the control cryogel. The combined scaffolds exhibited similar porosity and relative swelling ratio to the control cryogels. However, they had reduced elasticity, reduced absolute swelling capacity, and are potentially cytotoxic, which may affect their performance. This paper presents a novel approach to combine two scaffold types to retain the advantages of each scaffold type while mitigating their shortcomings.

Effect of Crosshead Speed and Volume Ratio on Compressive Mechanical Properties of Mono- and Double-Gyroid Structures Made of Inconel 718

The current development of additive technologies brings not only new possibilities but also new challenges. One of them is the use of regular cellular materials in various components and constructions so that they fully utilize the potential of porous structures and their advantages related to weight reduction and material-saving while maintaining the required safety and operational reliability of devices containing such components. It is therefore very important to know the properties of such materials and their behavior under different types of loads. The article deals with the investigation of the mechanical properties of porous structures made by the Direct Metal Laser Sintering (DMLS) of Inconel 718. Two types of basic cell topology, mono-structure Gyroid (G) and double-structure Gyroid + Gyroid (GG), with material volume ratios of 10, 15 and 20 %, were studied within our research to compare their properties under quasi-static compressive loading. The testing procedure was performed at ambient temperature with a servo-hydraulic testing machine at three different crosshead testing speeds. The recorded data were processed, while the stress-strain curves were plotted, and Young's modulus, the yield strength Re_0.2, and the stress at the first peak of the local maximum σ_LocMax were identified. The results showed the best behavior under compression load among the studied structures displayed by mono-structure Gyroid at 10 %. At the same time, it can be concluded that the wall thickness of the structure plays an important role in the compressive properties but on the other hand, crosshead speed doesn´t influence results significantly.

The design of strut/TPMS-based pore geometries in bioceramic scaffolds guiding osteogenesis and angiogenesis in bone regeneration

The pore morphology design of bioceramic scaffolds plays a substantial role in the induction of bone regeneration. Specifically, the effects of different scaffold pore geometry designs on angiogenesis and new bone regeneration remain unclear. Therefore, we fabricated Mg/Sr co-doped wollastonite bioceramic (MS-CSi) scaffolds with three different pore geometries (gyroid, cylindrical, and cubic) and compared their effects on osteogenesis and angiogenesis in vitro and in vivo. The MS-CSi scaffolds were fabricated by digital light processing (DLP) printing technology. The pore structure, mechanical properties, and degradation rate of the scaffolds were investigated. Cell proliferation on the scaffolds was evaluated using CCK-8 assays while angiogenesis was assessed using Transwell migration assays, tube formation assays, and immunofluorescence staining. The underlying mechanism was explored by western blotting. Osteogenic ability of scaffolds was evaluated by alkaline phosphatase (ALP) staining, western blotting, and qRT-PCR. Subsequently, a rabbit femoral defect model was prepared to compare differences in the scaffolds in osteogenesis and angiogenesis in vivo. Cell culture experiments showed that the gyroid pore scaffold downregulated YAP/TAZ phosphorylation and enhanced YAP/TAZ nuclear translocation, thereby promoting proliferation, migration, tube formation, and high expression of CD31 in human umbilical vein endothelial cells (HUVECs) while strut-based (cubic and cylindrical pore) scaffolds promoted osteogenic differentiation in bone marrow mesenchymal stem cells and upregulation of osteogenesis-related genes. The gyroid pore scaffolds were observed to facilitate early angiogenesis in the femoral-defect model rabbits while the strut-based scaffolds promoted the formation of new bone tissue. Our study indicated that the pore geometries and pore curvature characteristics of bioceramic scaffolds can be precisely tuned for enhancing both osteogenesis and angiogenesis. These results may provide new ideas for the design of bioceramic scaffolds for bone regeneration.

Calcium Carbonate Coating of 3D-Printed PLA Scaffolds Intended for Biomedical Applications

The incorporation of ceramic additives is the most commonly used strategy to improve the biofunctionality of polymer-based scaffolds intended for bone regeneration. By embedding ceramic particles as a coating, the functionality improvement in the polymeric scaffolds can be concentrated on the cell-surface interface, thus creating a more favourable environment for the adhesion and proliferation of osteoblastic cells. In this work, a pressure-assisted and heat-induced method to coat polylactic acid (PLA) scaffolds with calcium carbonate (CaCO₃) particles is presented for the first time. The coated scaffolds were evaluated by optical microscopy observations, a scanning electron microscopy analysis, water contact angle measurements, compression testing, and an enzymatic degradation study. The ceramic particles were evenly distributed, covered more than 60% of the surface, and represented around 7% of the coated scaffold weight. A strong bonding interface was achieved, and the thin layer of CaCO₃ (~20 µm) provided a significant increase in the mechanical properties (with a compression modulus improvement up to 14%) while also enhancing the surface roughness and hydrophilicity. The results of the degradation study confirmed that the coated scaffolds were able to maintain the pH of the media during the test (~7.6 ± 0.1), in contrast to the pure PLA scaffolds, for which a value of 5.07 ± 0.1 was obtained. The ceramic-coated scaffolds developed showed potential for further evaluations in bone tissue engineering applications.

Design Approach for Tuning the Hybrid Region of 3D-Printed Heterogeneous Structures: Modulating Mechanics and Energy Absorption Capacity

The functional hierarchical structures of the triply periodic minimal surface are receiving much attention in tissue engineering applications due to their lightweight and multifunctionality. However, current functionally graded structure design methods are not friendly to heterogeneous structures containing different orientations and different unit types and often face the problems of insufficient connection in the hybrid regions and low local stiffness. In this paper, an improved gradient structure design method was proposed, which solves the problem of insufficient connection between substructures by constructing hybrid region transition functions. Three improved heterogeneous structures were constructed using Primitive and Gyroid lattices and compared with the unimproved heterogeneous structure. Their mechanical properties, deformation mechanism, and energy absorption capacity were examined by finite element analysis and experiments. The results showed that the proposed design method can effectively solve the problems of insufficient connection and poor bearing capacity in the hybrid region between substructures. This method can not only ensure the full connection of the hybrid regions but also flexibly adjust the mechanical properties and energy absorption capacity as well as effectively expand the application range of the energy absorption. Overall, these findings provide valuable guidelines for designing gradient structures with disordered and hybrid features.

Additive manufacturing and performance of bioceramic scaffolds with different hollow strut geometries

Additively manufactured hollow-strut bioceramic scaffolds present a promising strategy towards enhanced performance in patient-tailored bone tissue engineering. The channels in such scaffolds offer pathways for nutrient and cell transport and facilitate effective osseointegration and vascularization. In this study, we report an approach for the slurry based additive manufacturing of modified diopside bioceramics that enables the production of hollow-strut scaffolds with diverse cross-sectional forms, distinguished by different configurations of channel and strut geometries. The prepared scaffolds exhibit levels of porosity and mechanical strength that are well suited for osteoporotic bone repair. Mechanical characterization in orthogonal orientations revealed that a square outer cross-section for hollow struts in woodpile scaffolds gives rise to levels of compressive strength that are higher than those of conventional solid cylindrical strut scaffolds despite a significantly lower density. Finite element analysis confirms that this improved strength arises from lower stress concentration in such geometries. It was shown that hollow struts in bioceramic scaffolds dramatically increase cell attachment and proliferation, potentially promoting new bone tissue formation within the scaffold channel. This work provides an easily controlled method for the extrusion-based 3D printing of hollow strut scaffolds. We show here how the production of hollow struts with controllable geometry can serve to enhance both the functional and mechanical performance of porous structures, with particular relevance for bone tissue engineering scaffolds.

A morphological, topological and mechanical investigation of gyroid, spinodoid and dual-lattice algorithms as structural models of trabecular bone

In this study, we evaluate the performance of three algorithms as computational models of trabecular bone architecture, through systematic evaluation of morphometric, topological, and mechanical properties. Here, we consider the widely-used gyroid lattice structure, the recently-developed spinodoid structure and a structure similar to Voronoi lattices introduced here as the dual-lattice. While all computational models were calibrated to recreate the trabecular tissue volume (e.g. BV/TV), it was found that both the gyroid- and spinodoid-based structures showed substantial differences in many other morphometric and topological parameters and, in turn, showed lower effective mechanical properties compared to trabecular bone. The newly-developed dual-lattice structures better captured both morphometric parameters and mechanical properties, despite certain differences being evident their topological configuration compared to trabecular bone. Still, these computational algorithms provide useful platforms to investigate trabecular bone mechanics and for designing biomimetic structures, which could be produced through additive manufacturing for applications that include bone substitutes, scaffolds and porous implants. Furthermore, the software for the creation of the structures has been added to the open source toolbox GIBBON and is therefore freely available to the community.

Surface Morphology, Compressive Behavior, and Energy Absorption of Graded Triply Periodic Minimal Surface 316L Steel Cellular Structures Fabricated by Laser Powder Bed Fusion

Laser powder bed fusion (LPBF) is an emerging technique for the fabrication of triply periodic minimal surface (TPMS) structures in metals. In this work, different TPMS structures such as Diamond, Gyroid, Primitive, Neovius, and Fisher-Koch S with graded relative densities are fabricated from 316L steel using LPBF. The graded TPMS samples are subjected to sandblasting to improve the surface finish before mechanical testing. Quasi-static compression tests are performed to study the deformation behavior and energy absorption capacity of TPMS structures. The results reveal superior stiffness and energy absorption capabilities for the graded TPMS samples compared to the uniform TPMS structures. The Fisher-Koch S and Primitive samples show higher strength whereas the Fisher-Koch S and Neovius samples exhibit higher elastic modulus. The Neovius type structure shows the highest energy absorption up to 50% strain among all the TPMS structures. The Gibson-Ashby coefficients are calculated for the TPMS structures, and it is found that the C₂ values are in the range suggested by Gibson and Ashby while C₁ values differ from the proposed range.

Fabrication of multilevel porous structure networks on Nb-Ta-Ti alloy scaffolds and the effects of surface characteristics on behaviors of MC3T3-E1 cells

Porous Nb-25Ta-25Ti alloys (60% porosity and 100-600 μm pore size) for bone implant applications were manufactured combining impregnation and sintering methods. Surfaces with porous micro-nanostructured networks on Nb-Ta-Ti alloys were successfully modified by various surface pre-treatments (acid etching, alkali-heat treatment and annealing treatment). Surface characteristics and Ca-P layer deposition behaviors of the multilevel structured porous Nb-Ta-Ti alloys were investigated by conducting various tests, including x-ray diffraction, scanning electron microscopy, energy-dispersive x-ray, atomic force microscopy and optical contact angle measurement. In particular, bulk Nb-Ta-Ti alloys were also used as mutual control. The results demonstrated that the porous alloy exhibited a unique multilevel porous structure with macro-networks and micro-pits after pre-treatments. The surface passive TiO₂/Nb₂O₅/Ta₂O₅layers on Nb-Ta-Ti alloys were partially dissolved by the corrosive attack of hydroxyl ions during alkali heat treatment. In addition, subsequent annealing treatment increased the density of the gel layers formed during alkali heat treatment. After immersion in SBF for 14 d, a continuous relatively uniform apatite layer was formed on the multilevel structured surfaces. Moreover, the mechanism of surface mineralization can be construed as electrostatic interactions between substrates and ions. Furthermore,in vitrocell culture showed that Nb-Ta-Ti alloys had a good biocompatibility and the multilevel porous structure could enhance the cellular behaviors including: cell adhesion and spreading.

The Influence of the Structure Parameters on the Mechanical Properties of Cylindrically Mapped Gyroid TPMS Fabricated by Selective Laser Melting with 316L Stainless Steel Powder

The development of additive manufacturing techniques has made it possible to produce porous structures with complex geometry with unique properties as potential candidates for energy absorption, heat dissipation, biomedical, and vibration control application. Recently, there has been increased interest in additively manufacturing porous structures based on triply periodic minimal surfaces (TPMS) topology. In this paper, the mechanical properties and energy absorption abilities of cylindrical mapped TPMS structures with shell gyroid unit cells fabricated by selective laser melting (SLM) with 316L stainless steel under compression loading were investigated. Based on the experimental study, it was found that tested structures exhibited two different deformation modes. There is also a relationship between the number and shapes of unit cells in the structure and the elastic modulus, yield strength, plateau stress, and energy absorption. These results can be used to design and manufacture more efficient lightweight parts lattices for energy absorbing applications, e.g., in the field of biomedical and bumpers applications. The deformation mode for each tested sample was also presented on the records obtained from the ARAMIS system.

Design and Analysis of Biomedical Scaffolds Using TPMS-Based Porous Structures Inspired from Additive Manufacturing

Gyroid (G) and primitive (P) porous structures have multiple application areas, ranging from thermal to mechanical, and fall in the complex triply periodic minimal surface (TPMS) category. Such intricate bioinspired constructs are gaining attention because they meet both biological and mechanical requirements for osseous reconstruction. The study aimed to develop G and P structures with varying porosity levels from 40% to 80% by modulating the strut thickness to proportionally resemble the stiffness of host tissue. The performance characteristics were evaluated using Ti6Al4V and important relationships between feature dimension, strut thickness, porosity, and stiffness were established. Numerical results showed that the studied porous structures could decrease stiffness from 107 GPa (stiffness of Ti6Al4V) to the range between 4.21 GPa to 29.63 GPa of varying porosities, which matches the human bone stiffness range. Furthermore, using this foundation, a subject-specific scaffold (made of P unit cells with an 80% porosity) was developed to reconstruct segmental bone defect (SBD) of the human femur, demonstrating a significant decrease in the stress shielding effect. Stress transfer on the bone surrounded by a P scaffold was compared with a solid implant which showed a net increase of stress transfer of 76% with the use of P scaffold. In the conclusion, future concerns and recommendations are suggested.

Effect of Surface Curvature on the Mechanical and Mass-Transport Properties of Additively Manufactured Tissue Scaffolds with Minimal Surfaces

The design of scaffolds for tissue engineering has to consider two trade-off properties: mechanical and mass-transport properties. This is particularly true for additively manufactured scaffolds with the structures of minimal surfaces, and notably, the influence of the surface curvature of the structure on the mechanical and mass-transport properties remains unclear. This work presents our study on the scaffolds designed with the structure of triply periodic minimal surfaces (TPMS), with a focus on discovering the influence of surface curvature on the mechanical response and the mass-transport property or permeability of the scaffolds. Based on the entropy weight fuzzy comprehensive evaluation method, a model representative of both mechanical and permeable properties of scaffolds was developed; scanning electron microscopy (SEM) and finite element analysis (FEA) were also used to reveal the influence mechanism of curvature on structural fracture and deformation behavior. AlSi10Mg samples of scaffolds designed with different surface curvatures were manufactured using selective laser melting (SLM), and their mechanical and permeable properties were examined and characterized by both experiments and simulations. Our results illustrate that at the same porosity, the more concentrated the curvature distribution of the same type of unit, the better trade-off mechanical and mass-transport properties the scaffolds have. Particularly, at the porosity of 55%, the compressive elastic modulus and permeability of the Dte structure are increased by 2.03 times and 1.95 times compared with the Diamond unit, respectively. The fusion structure can greatly improve permeability performance at the cost of mechanical properties. Our results also show that porosity has the greatest influence on mechanical and permeable properties, followed by the surface curvature. The study illustrates that the surface curvature has a significant influence on the mechanical and permeable properties of scaffolds, and that the developed scaffold performance evaluation scheme is an effective means for the optimization and evaluation of scaffold performance.

Numerical Evaluation of a Porous Tibial-Knee Implant using Gyroid Structure

BACKGROUND

Porous materials are recommended for orthopedic applications as they eliminate issues of interfacial instability with tissues and reduce mechanical mismatch of the young's modulus.

OBJECTIVE

The current research provides a finite element analysis (FEA) to investigate porous gyroid Ti6Al4V structure compared to a solid stem model for human tibial-knee implantation of total knee replacement (TKR).

MATERIAL AND METHODS

In this study, the implant proximal portion was designed as porous gyroid Ti6Al4V structure with 500 µm pore size. CATIA V5R18 was used for modeling both gyroid and full solid models. Structural analysis was carried out using ANSYS R18.1 to evaluate the implant performance.

RESULTS

After gyroid implantation, the maximum von-Mises stress obtained under the tibial tray was increased to 10.081 MPa. Also, the maximum shear stress at the stem/bone interface was reduced to 0.7347 MPa. The stress concentration at the stem tip and the bone strain energy were also improved. The minimum factor of safety is 4.6 for the gyroid porous implant. A proof of concept model was additively manufactured successfully with pore size 577.7733 ± 34.762 µm.

CONCLUSION

The results indicated enhanced clinical performance of the porous tibial-knee implant compared to the solid titanium implant via increasing the maximum von-Mises bone stresses and decreasing the maximum shear stress at the bone/implant interface.

Morphological and mechanical characterisation of three-dimensional gyroid structures fabricated by electron beam melting for the use as a porous biomaterial

Additive manufactured porous biomaterials based on triply periodic minimal surfaces (TPMS) are a highly discussed topic in the literature. With their unique properties in terms of open porosity, large surface area and surface curvature, they are considered to have bone mimicking properties and remarkable osteogenic potential. In this study, scaffolds of gyroid unit cells of different sizes consisting of a Ti6Al4V alloy were manufactured additively by electron beam melting (EBM). The scaffolds were analysed by micro-computed tomography (micro-CT) to determine their morphological characteristics and, subsequently, subjected to mechanical tests to investigate their quasi-static compressive properties and fatigue resistance. All scaffolds showed an average open porosity of 71-81%, with an average pore size of 0.64-1.41 mm, depending on the investigated design. The design with the smallest unit cell shows the highest quasi-elastic gradient (QEG) as well as the highest compressive offset stress and compression strength. Furthermore, the fatigue resistance of all unit cell size (UCS) variations showed promising results. In detail, the smallest unit cells achieved fatigue strength at 10⁶ cycles at 45% of their compressive offset stress, which is comparatively good for additively manufactured porous biomaterials. In summary, it is demonstrated that the mechanical properties can be significantly modified by varying the unit cell size, thus enabling the scaffolds to be specifically tailored to avoid stress shielding and ensure implant safety. Together with the morphological properties of the gyroid unit cells, the fabricated scaffolds represent a promising approach for use as a bone substitute material.

Up-Cycling of LCD Glass by Additive Manufacturing of Porous Translucent Glass Scaffolds

Additive manufacturing technologies, compared to conventional shaping methods, offer great opportunities in design versatility, for the manufacturing of highly porous ceramic components. However, the application to glass powders, later subjected to viscous flow sintering, involves significant challenges, especially in shape retention and in the achievement of a substantial degree of translucency in the final products. The present paper disclosed the potential of glass recovered from liquid crystal displays (LCD) for the manufacturing of highly porous scaffolds by direct ink writing and masked stereolithography of fine powders mixed with suitable organic additives, and sintered at 950 °C, for 1-1.5 h, in air. The specific glass, featuring a relatively high transition temperature (T_g~700 °C), allowed for the complete burn-out of organics before viscous flow sintering could take place; in addition, translucency was favored by the successful removal of porosity in the struts and by the resistance of the used glass to crystallization.

Different Approaches for Manufacturing Ti-6Al-4V Alloy with Triply Periodic Minimal Surface Sheet-Based Structures by Electron Beam Melting

Targeting biomedical applications, Triply Periodic Minimal Surface (TPMS) gyroid sheet-based structures were successfully manufactured for the first time by Electron Beam Melting in two different production Themes, i.e., inputting a zero (Wafer Theme) and a 200 µm (Melt Theme) wall thickness. Initial assumption was that in both cases, EBM manufacturing should yield the structures with similar mechanical properties as in a Wafer-mode, as wall thickness is determined by the minimal beam spot size of ca 200 µm. Their surface morphology, geometry, and mechanical properties were investigated by means of electron microscopy (SEM), X-ray Computed Tomography (XCT), and uniaxial tests (both compression and tension). Application of different manufacturing Themes resulted in specimens with different wall thicknesses while quasi-elastic gradients for different Themes was found to be of 1.5 GPa, similar to the elastic modulus of human cortical bone tissue. The specific energy absorption at 50% strain was also similar for the two types of structures. Finite element simulations were also conducted to qualitatively analyze the deformation process and the stress distribution under mechanical load. Simulations demonstrated that in the elastic regime wall, regions oriented parallel to the load are primarily affected by deformation. We could conclude that gyroids manufactured in Wafer and Melt Themes are equally effective in mimicking mechanical properties of the bones.

Mechanical Properties of Porous Structures for Dental Implants: Experimental Study and Computational Homogenization

A combined experimental and numerical study on titanium porous microstructures intended to interface the bone tissue and the solid homogeneous part of a modern dental implant is presented. A specific class of trabecular geometries is compared to a gyroid structure. Limitations associated with the application of the adopted selective laser melting technology to small microstructures with a pore size of 500 μm are first examined experimentally. The measured effective elastic properties of trabecular structures made of Ti6Al4V material support the computational framework based on homogenization with the difference between the measured and predicted Young’s moduli of the Dode Thick structure being less than 5%. In this regard, the extended finite element method is promoted, particularly in light of the complex sheet gyroid studied next. While for plastic material-based structures a close match between experiments and simulations was observed, an order of magnitude difference was encountered for titanium specimens. This calls for further study and we expect to reconcile this inconsistency with the help of computational microtomography.

Compressive Behaviour of Additively Manufactured Lattice Structures: A Review

Additive manufacturing (AM) technology has undergone an evolutionary process from fabricating test products and prototypes to fabricating end-user products—a major contributing factor to this is the continuing research and development in this area. AM offers the unique opportunity to fabricate complex structures with intricate geometry such as the lattice structures. These structures are made up of struts, unit cells, and nodes, and are being used not only in the aerospace industry, but also in the sports technology industry, owing to their superior mechanical properties and performance. This paper provides a comprehensive review of the mechanical properties and performance of both metallic and non-metallic lattice structures, focusing on compressive behaviour. In particular, optimisation techniques utilised to optimise their mechanical performance are examined, as well the primary factors influencing mechanical properties of lattices, and their failure mechanisms/modes. Important AM limitations regarding lattice structure fabrication are identified from this review, while the paucity of literature regarding material extruded metal-based lattice structures is discussed.

Histological examination of a retrieved custom-made 3D-printed titanium vertebra : Do the fine details obtained by additive manufacturing really promote osteointegration?

PURPOSE

In the present report it is described the design, the manufacturing and the successful surgical implant of one of the first 3D custom titanium vertebra realized with Additive Manufacturing technique and its use for the spinal reconstruction after en-bloc resection for primary osteogenic sarcoma.

METHODS

Clinical case presentation and the design of the 3D custom titanium vertebra was reported. It was also described the complex procedures adopted to evaluate the retrieved device from the histological point of view, as a tumor relapse hit the patient, one year after the reconstruction procedure.

RESULTS

The histological evaluation confirmed that the resection technique exerts an important role in promoting bone formation: vertebral body osteotomies favored the reconstruction procedure and maximized the contact area between host bone/vertebral prosthesis thus favoring the bone tissue penetration and device colonization.

CONCLUSION

The sharing of these results is very important as they represent the starting point for improving the knowledge starting from the evidence obtained in a challenging clinical condition and with post-operative treatments that could be never reproduced in preclinical model.

Investigation of Compressive and Tensile Behavior of Stainless Steel/Dissolvable Aluminum Bimetallic Composites by Finite Element Modeling and Digital Image Correlation

This study reports fabrication, mechanical characterization, and finite element modeling of a novel lattice structure based bimetallic composite comprising 316L stainless steel and a functional dissolvable aluminum alloy. A net-shaped 316L stainless steel lattice structure composed of diamond unit cells was fabricated by selective laser melting (SLM). The cavities in the lattice structure were then filled through vacuum-assisted melt infiltration to form the bimetallic composite. The bulk aluminum sample was also cast using the same casting parameters for comparison. The compressive and tensile behavior of 316L stainless steel lattice, bulk dissolvable aluminum, and 316L stainless steel/dissolvable aluminum bimetallic composite is studied. Comparison between experimental, finite element analysis (FEA), and digital image correlation (DIC) results are also investigated in this study. There is no notable difference in the tensile behavior of the lattice and bimetallic composite because of the weak bonding in the interface between the two constituents of the bimetallic composite, limiting load transfer from the 316L stainless steel lattice to the dissolvable aluminum matrix. However, the aluminum matrix is vital in the compressive behavior of the bimetallic composite. The dissolvable aluminum showed higher Young's modulus, yield stress, and ultimate stress than the lattice and composite in both tension and compression tests, but much less elongation. Moreover, FEA and DIC have been demonstrated to be effective and efficient methods to simulate, analyze, and verify the experimental results through juxtaposing curves on the plots and comparing strains of critical points by checking contour plots.

Design and Fabrication of a Customized Partial Hip Prosthesis Employing CT-Scan Data and Lattice Porous Structures

As a larger elderly human population is expected worldwide in the next 30 years, the occurrence of aging-associated illnesses will also be increased. The use of prosthetic devices by this population is currently important and will be even more dramatic in the near future. Hence, the design of prosthetic devices able to reduce some of the problems associated with the use of current components, such as stress shielding, reduced mobility, infection, discomfort, etc., becomes relevant. The use of additive manufacturing (AM) and the design fabrication of self-supported cellular structures in the biomedical area have opened up important opportunities for controlling the physical and mechanical properties of hip implants, resulting in specific benefits for the patients. Different studies have reported the development of hip prosthetic designs employing AM, although there are still opportunities for improvement when it comes to customized design and tuning of the physical and mechanical properties of such implants. This work shows the design and manufacture by AM of a personalized stainless-steel partial hip implant using tomography data and self-supported triply periodic minimal surface (TPMS) cell structures; the design considers dimensional criteria established by international standards. By employing tomography data, the external dimensions of the implant were established and the bone density of a specific patient was calculated; the density and mechanical properties in compression of the implant were modulated by employing an internal gyroid-type cell structure. Using such a cell structure, the patient's bone density was emulated; also, the mechanical properties of the implant were fine-tuned in order to make them comparable to those reported for the bone tissue replaced by the prosthesis. The implant design and manufacturing methodology developed in this work considered the clinical condition of a specific patient and can be reproduced and adjusted for different types of bone tissue qualities for specific clinical requirements.

Reducing the Structural Mass of Large Direct Drive Wind Turbine Generators through Triply Periodic Minimal Surfaces Enabled by Hybrid Additive Manufacturing

As the power output of direct drive generators increases, they become prohibitively large with much of this material structural support. In this work, implicit modeling was coupled to finite element analysis through a genetic algorithm variant to automate lattice optimization for the rotor of a 5 MW permanent magnet direct drive generator for mass reduction. Three triply periodic minimal surfaces (TPMS) were chosen: Diamond, Schwartz Primitive, and Gyroid. Parameter and functionally graded lattice optimization were employed to reduce mass within deflection criteria. Inactive mass for the 5 MW Diamond, Schwartz Primitive, and Gyroid optimized designs was 10,043, 10,858, and 10,990 kg, respectively. The Schwartz Primitive rotor resulted in a 34% reduction in inactive mass compared to a 5 MW baseline design. Radial and axial deflections were below the critical limit of 0.65 and 32.17 mm, respectively. The lowest torsional deflection was seen in the Schwartz Primitive TPMS lattice at 3.89 mm. Based on these designs, hybrid additive manufacturing with investment casting was used to validate manufacturability in metal. A fused deposition modeling (FDM) TPMS topology was printed for validation of the FEA results. Comparison between digital image correlation of the FDM printed design and FEA design resulted in a 6.7% deformation difference for equivalent loading conditions.

Compressive anisotropy of sheet and strut based porous Ti-6Al-4V scaffolds

Porous metallic scaffolds show promise in orthopedic applications due to favorable mechanical and biological properties. In vivo stress conditions on orthopedic implants are complex, often including multiaxial loading across off axis orientations. In this study, unit cell orientation was rotated in the XZ plane of a strut-based architecture, Diamond Crystal, and two sheet-based, triply periodic minimal surface (TPMS) architectures, Schwartz D and Gyroid. Sheet-based architectures exhibited higher peak compressive strength, yield strength and strain at peak stress than the strut-based architecture. All three topologies demonstrated an orientational dependence in mechanical properties. There was a greater degree of anisotropy (49%) in strut-based architecture than in either TPMS architectures (18-21%). These results support the superior strength and advantageous isotropic mechanical properties of sheet-based TPMS architectures relative to strut-based architectures, as well as highlighting the importance of considering anisotropic properties of lattice scaffolds for use in tissue engineering.

Powder based additive manufacturing for biomedical application of titanium and its alloys: a review

Powder based additive manufacturing (AM) technology of Ti and its alloys has received great attention in biomedical applications owing to its advantages such as customized fabrication, potential to be cost-, time-, and resource-saving. The performance of additive manufactured implants or scaffolds strongly depends on various kinds of AM technique and the quality of Ti and its alloy powders. This paper has specifically covered the process of commonly used powder-based AM technique and the powder production of Ti and its alloy. The selected techniques include laser-based powder bed fusion of metals (PBF-LB/M), electron beam powder bed fusion of metals (PBF-EB/M), and directed energy deposition utilized in the production of the biomaterials are discussed as well as the powder fed system of binder jetting. Moreover, titanium based powder production methods such as gas atomization, plasma atomization, and plasma rotating electrode process are also discussed.

Additive manufacturing of PLA-based scaffolds intended for bone regeneration and strategies to improve their biological properties

Polylactic acid (PLA) is one of the most commonly used materials in the biomedical sector because of its processability, mechanical properties and biocompatibility. Among the different techniques that are feasible to process this biomaterial, additive manufacturing (AM) has gained attention recently, as it provides the possibility of tuning the design of the structures. This flexibility in the design stage allows the customization of the parts in order to optimize their use in the tissue engineering field. In the recent years, the application of PLA for the manufacture of bone scaffolds has been especially relevant, since numerous studies have proven the potential of this biomaterial for bone regeneration. This review contains a description of the specific requirements in the regeneration of bone and how the state of the art have tried to address them with different strategies to develop PLA-based scaffolds by AM techniques and with improved biofunctionality.

Mechanical behavior of in-situ alloyed Ti6Al4V(ELI)-3 at.% Cu lattice structures manufactured by laser powder bed fusion and designed for implant applications

In the present study, cellular lattice structures for implant applications are reported for the first-time incorporating copper directly by in-situ alloying in the laser powder bed fusion process. The aim to incorporate 3 at.% Cu into Ti6Al4V(ELI) is selected for improved antibacterial properties while maintaining appropriate mechanical properties. Previously, topologically optimized Ti6Al4V(ELI) lattice structures were successfully designed, manufactured and studied for implant applications. The development of a new alloy produced by in-situ alloying of elemental powder mixture of Ti6Al4V(ELI) and pure Cu powders was used here for the production of identical lattice structures with improved antibacterial properties. One of the same as-designed CAD models was used for the manufacturing of these lattices compared to previous work on pure Ti6Al4V(ELI) lattices, making direct comparison of mechanical properties possible. Similar manufacturability highlights the applicability of this alloying technique to other lattice designs. Microstructural characterization was performed by optical and electron microscopies, as well as microCT. Mechanical characterization was performed by means of compression tests and hardness measurements. Results showed that in-situ alloying with copper leads to the formation of localized Cu-rich regions, refinement of martensitic phase and the formation of CuTi₂ intermetallic precipitates, which increased the hardness and strength of the material. Deviations in wall thickness between the as-designed and as-manufactured lattices led to anisotropy of the mechanical properties of the lattices. Higher compressive strength values were obtained when thicker walls were oriented along the loading direction. Nevertheless, alloying with Cu had a higher impact on the compressive strength of lattice structure than the wall thickness deviations. The direct in-situ alloying of copper in Ti6Al4V(ELI) is a promising route for direct manufacturing of antibacterial implants.

Comparison of Fused Deposition Modeling and Color Jet 3D Printing Technologies for the Printing of Mathematical Geometries

Many mathematical geometries act as an optimal structure for functional applications and have always been an area of interest in the research field. Their topology offers properties which are crucial and can be used effectively in various domains. Apart from that, some have a resemblance to naturally occurring compounds which can help us to study their different transformations and behavior. In this paper, we present two such geometries, first, gyroid, which is an iso-minimal surface and second a three-crossing knot, also known as trefoil knot. The structure of gyroid makes it unique and is considered suitable in developing energy-absorbing, structural and lightweight applications. Similarly, some types of knots resemble the DNA structure and have found use in molecular chemistry. This paper discusses different application areas of these geometries. Further, this paper presents modeling and printing by using fused deposition modeling (FDM) and color jet printing (CJP). Comparative analysis has been done by considering various parameters. This paper discusses the potential of these two rapid prototyping technologies and their suitability for specific printing applications.

Porous Scaffold Design for Additive Manufacturing in Orthopedics: A Review

With the increasing application of orthopedic scaffolds, a dramatically increasing number of requirements for scaffolds are precise. The porous structure has been a fundamental design in the bone tissue engineering or orthopedic clinics because of its low Young's modulus, high compressive strength, and abundant cell accommodation space. The porous structure manufactured by additive manufacturing (AM) technology has controllable pore size, pore shape, and porosity. The single unit can be designed and arrayed with AM, which brings controllable pore characteristics and mechanical properties. This paper presents the current status of porous designs in AM technology. The porous structures are stated from the cellular structure and the whole structure. In the aspect of the cellular structure, non-parametric design and parametric design are discussed here according to whether the algorithm generates the structure or not. The non-parametric design comprises the diamond, the body-centered cubic, and the polyhedral structure, etc. The Voronoi, the Triply Periodic Minimal Surface, and other parametric designs are mainly discussed in parametric design. In the discussion of cellular structures, we emphasize the design, and the resulting biomechanical and biological effects caused by designs. In the aspect of the whole structure, the recent experimental researches are reviewed on uniform design, layered gradient design, and layered gradient design based on topological optimization, etc. These parts are summarized because of the development of technology and the demand for mechanics or bone growth. Finally, the challenges faced by the porous designs and prospects of porous structure in orthopedics are proposed in this paper.

Visualizing Magnetic Structure in 3D Nanoscale Ni-Fe Gyroid Networks

Arrays of interacting 2D nanomagnets display unprecedented electromagnetic properties via collective effects, demonstrated in artificial spin ices and magnonic crystals. Progress toward 3D magnetic metamaterials is hampered by two challenges: fabricating 3D structures near intrinsic magnetic length scales (sub-100 nm) and visualizing their magnetic configurations. Here, we fabricate and measure nanoscale magnetic gyroids, periodic chiral networks comprising nanowire-like struts forming three-connected vertices. Via block copolymer templating, we produce Ni₇₅Fe₂₅ single-gyroid and double-gyroid (an inversion pair of single-gyroids) nanostructures with a 42 nm unit cell and 11 nm diameter struts, comparable to the exchange length in Ni-Fe. We visualize their magnetization distributions via off-axis electron holography with nanometer spatial resolution and interpret the patterns using finite-element micromagnetic simulations. Our results suggest an intricate, frustrated remanent state which is ferromagnetic but without a unique equilibrium configuration, opening new possibilities for collective phenomena in magnetism, including 3D magnonic crystals and unconventional computing.

Porous Tantalum and Titanium in Orthopedics: A Review

Porous metal is metal with special porous structures, which can offer high biocompatibility and low Young's modulus to satisfy the need for orthopedic applications. Titanium and tantalum are the most widely used porous metals in orthopedics due to their excellent biomechanical properties and biocompatibility. Porous titanium and tantalum have been studied and applied for a long history until now. Here in this review, various manufacturing methods of titanium and tantalum porous metals are introduced. Application of these porous metals in different parts of the body are summarized, and strengths and weaknesses of these porous metal implants in clinical practice are discussed frankly for future improvement from the viewpoint of orthopedic surgeons. Then according to the requirements from clinics, progress in research for clinical use is illustrated in four aspects. Various creative designs of microporous and functionally gradient structure, surface modification, and functional compound systems of porous metal are exhibited as reference for future research. Finally, the directions of orthopedic porous metal development were proposed from the clinical view based on the rapid progress of additive manufacturing. Controllable design of both macroscopic anatomical bionic shape and microscopic functional bionic gradient porous metal, which could meet the rigorous mechanical demand of bone reconstruction, should be developed as the focus. The modification of a porous metal surface and construction of a functional porous metal compound system, empowering stronger cell proliferation and antimicrobial and antineoplastic property to the porous metal implant, also should be taken into consideration.

41 Cases of Treatment of Cranial Cruciate Ligament Rupture with Porous TTA: Three Years of Follow Up

Tibial Tuberosity Advancement (TTA) is a surgical technique based on a linear osteotomy that determines a cranial advancement of the tibial tuberosity in patients suffering from cranial cruciate ligament rupture (CCL). The aim is to neutralize the cranial tibial thrust (CTT) and to reach a 90° angle between the patellar tendon and the tibial plateau with a physiological knee extension of 135°. In our study, a Ti6AI4V ELI (Titanium Aluminium Vanadium) titanium scaffold for the Porous TTA, with excellent properties of osteointegration and osteoconduction when subjected to cyclic loading has been adopted. Based on the previous scientific work on an ovine model, the use of this type of porous scaffolds has subverted the previous models. Scaffold production technology is based on direct mechanical manufacturing called Electron Beam Melting (EBM). For this study, 41 dogs, different breeds, medium-large size, weighing between 10 and 80 kg, aged between 1 and 13 years, were enrolled. The inclusion criteria were based on clinical evaluations (different gaits), drawer test and tibial compression, LOAD score (Liverpool Osteoarthritis in Dogs questionnaire), radiographic diagnosis in sedation with a 135° positioning of the joint and baropodometric investigations (Stance Analyzer). The results show that Porous TTA is an excellent method for functional recovery of the knee joint following the partial and total rupture of the CCL.

Cell Behavior on 3D Ti-6Al-4 V Scaffolds with Different Porosities

Porous titanium (Ti) and its alloys fabricated by additive manufacturing (AM) techniques have attractive potential for dental and bone defect repair fields. Understanding the relationship between cells and the surface of the as-built three-dimensional (3D) scaffold interactions is not only necessary for tissue engineering but also promising for improving the fabrication process in the manufacture of artificial implants by AM technology. In this study, we have aimed to investigate the cell behavior including adhesion and proliferation of fibroblasts (L929) on Ti-6Al-4 V scaffolds fabricated by the electron beam melting method. The porosities of Ti-6Al-4 V scaffolds are 0% (compact), 60%, and 70%, respectively. Different cell behaviors have been observed from all of the specimens after 4 and 8 days of cell incubation. The present result indicates that, besides the surface roughness, the surface topography of specimens should also be taken into consideration to investigate the interaction between implants and cells. Therefore, this study would provide several possibilities for improving the osteointegration functions of the manufactured porous metallic implants in orthopedic and dental applications.

Additive manufacturing technology for porous metal implant applications and triple minimal surface structures: A review

Recently, the fabrication methods of orthopedic implants and devices have been greatly developed. Additive manufacturing technology allows the production of complex structures with bio-mimicry features, and has the potential to overcome the limitations of conventional fabrication methods. This review explores open-cellular structural design for porous metal implant applications, in relation to the mechanical properties, biocompatibility, and biodegradability. Several types of additive manufacturing techniques including selective laser sintering, selective laser melting, and electron beam melting, are discussed for different applications. Additive manufacturing through powder bed fusion shows great potential for the fabrication of high-quality porous metal implants. However, the powder bed fusion technique still faces two major challenges: it is high cost and time-consuming. In addition, triply periodic minimal surface (TPMS) structures are also analyzed in this paper, targeting the design of metal implants with an enhanced biomorphic environment.

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Orthopedic implants should exhibit biocompatibility and biomechanical compatibility.

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The elastic modulus of an implant should closely match that of natural bone.

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TPMS structures possess excellent biomimicry in supporting cell activities.

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AM technology allows the production of bone implant with biomimicry features.

Three-dimensionally printed vertebrae with different bone densities for surgical training

PURPOSE

To evaluate whether 3D-printed vertebrae offer realistic haptic simulation of posterior pedicle screw placement and decompression surgery with normal to osteoporotic-like properties.

METHODS

A parameterizable vertebra model was developed, adjustable in cortical and cancellous bone thicknesses. Based on this model, five different L3 vertebra types (α, β, γ1, γ2, and γ3) were designed and fourfold 3D-printed. Four spine surgeons assessed each vertebra type and a purchasable L3 Sawbones vertebra. Haptic behavior of six common steps in posterior spine surgery was rated from 1 to 10: 1-2: too soft, 3-4: osteoporotic, 5-6: normal, 7-8: hard, and 9-10: too hard. Torques were measured during pedicle screw insertion.

RESULTS

In total, 24 vertebrae (six vertebra types times four examiners) were evaluated. Mean surgical assessment scores were: α 3.2 ± 0.9 (osteoporotic), β 1.9 ± 0.7 (too soft), γ1 4.7 ± 0.9 (osteoporotic-normal), γ2 6.3 ± 1.1 (normal), and γ3 7.5 ± 1.1 (hard). All surgeons considered the 3D-printed vertebrae α, γ1, and γ2 as more realistic than Sawbones vertebrae, which were rated with a mean score of 4.1 ± 1.7 (osteoporotic-normal). Mean pedicle screw insertion torques (Ncm) were: α 32 ± 4, β 12 ± 3, γ1 74 ± 4, γ2 129 ± 13, γ3 196 ± 34 and Sawbones 90 ± 11.

CONCLUSIONS

In this pilot study, 3D-printed vertebrae displayed haptically and biomechanically realistic simulation of posterior spinal procedures and outperformed Sawbones. This approach enables surgical training on bone density-specific vertebrae and provides an outlook toward future preoperative simulation on patient-specific spine replicas. These slides can be retrieved under Electronic Supplementary Material.

A Bioactive Hydrogel and 3D Printed Polycaprolactone System for Bone Tissue Engineering

In this study, a hybrid system consisting of 3D printed polycaprolactone (PCL) filled with hydrogel was developed as an application for reconstruction of long bone defects, which are innately difficult to repair due to large missing segments of bone. A 3D printed gyroid scaffold of PCL allowed a larger amount of hydrogel to be loaded within the scaffolds as compared to 3D printed mesh and honeycomb scaffolds of similar volumes and strut thicknesses. The hydrogel was a mixture of alginate, gelatin, and nano-hydroxyapatite, infiltrated with human mesenchymal stem cells (hMSC) to enhance the osteoconductivity and biocompatibility of the system. Adhesion and viability of hMSC in the PCL/hydrogel system confirmed its cytocompatibility. Biomineralization tests in simulated body fluid (SBF) showed the nucleation and growth of apatite crystals, which confirmed the bioactivity of the PCL/hydrogel system. Moreover, dissolution studies, in SBF revealed a sustained dissolution of the hydrogel with time. Overall, the present study provides a new approach in bone tissue engineering to repair bone defects with a bioactive hybrid system consisting of a polymeric scaffold, hydrogel, and hMSC.

Fatigue behaviour of NiTi shape memory alloy scaffolds produced by SLM, a unit cell design comparison

Selective laser melting (SLM) is an additive manufacturing technique able to produce complex functional parts via successively melting layers of metal powder. This process grants the freedom to design highly complex scaffold components to allow bone ingrowth and aid mechanical anchorage. This paper investigates the compression fatigue behaviour of three different unit cells (octahedron, cellular gyroid and sheet gyroid) of SLM nitinol scaffolds. It was found that triply periodic minimal surfaces display superior static mechanical properties in comparison to conventional octahedron beam lattice structures at identical volume fractions. Fatigue resistance was also found to be highly geometry dependent due to the effects of AM processing techniques on the surface topography and notch sensitivity. Geometries minimising nodal points and the staircase effect displayed the greatest fatigue resistance when normalized to yield strength. Furthermore oxygen analysis showed a large oxygen uptake during SLM processing which must be altered to meet ASTM medical grade standards and may significantly reduce fatigue life. These achieved fatigue properties indicate that NiTi scaffolds produced via SLM can provide sufficient mechanical support over an implants lifetime within stress range values experienced in real life.