1
|
Moiduddin K, Mian SH, Elseufy SM, Alkhalefah H, Ramalingam S, Sayeed A. Polyether-Ether-Ketone (PEEK) and Its 3D-Printed Quantitate Assessment in Cranial Reconstruction. J Funct Biomater 2023; 14:429. [PMID: 37623673 PMCID: PMC10455463 DOI: 10.3390/jfb14080429] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/09/2023] [Revised: 07/31/2023] [Accepted: 08/14/2023] [Indexed: 08/26/2023] Open
Abstract
Three-dimensional (3D) printing, medical imaging, and implant design have all advanced significantly in recent years, and these developments may change how modern craniomaxillofacial surgeons use patient data to create tailored treatments. Polyether-ether-ketone (PEEK) is often seen as an attractive option over metal biomaterials in medical uses, but a solid PEEK implant often leads to poor osseointegration and clinical failure. Therefore, the objective of this study is to demonstrate the quantitative assessment of a custom porous PEEK implant for cranial reconstruction and to evaluate its fitting accuracy. The research proposes an efficient process for designing, fabricating, simulating, and inspecting a customized porous PEEK implant. In this study, a CT scan is utilized in conjunction with a mirrored reconstruction technique to produce a skull implant. In order to foster cell proliferation, the implant is modified into a porous structure. The implant's strength and stability are examined using finite element analysis. Fused filament fabrication (FFF) is utilized to fabricate the porous PEEK implants, and 3D scanning is used to test its fitting accuracy. The results of the biomechanical analysis indicate that the highest stress observed was approximately 61.92 MPa, which is comparatively low when compared with the yield strength and tensile strength of the material. The implant fitting analysis demonstrates that the implant's variance from the normal skull is less than 0.4436 mm, which is rather low given the delicate anatomy of the area. The results of the study demonstrate the implant's endurance while also increasing the patient's cosmetic value.
Collapse
Affiliation(s)
- Khaja Moiduddin
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
| | - Syed Hammad Mian
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
| | | | - Hisham Alkhalefah
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
| | - Sundar Ramalingam
- Department of Oral and Maxillofacial Surgery, College of Dentistry and Dental University Hospital, King Saud University Medical City, Riyadh 11545, Saudi Arabia
| | - Abdul Sayeed
- Department of Mechanical Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia
| |
Collapse
|
2
|
Arsentev MY, Sysoev EI, Makogon AI, Balabanov SV, Sychev MM, Hammouri MH, Moshnikov VA. High-Throughput Screening of 3D-Printed Architected Materials Inspired by Crystal Lattices: Procedure, Challenges, and Mechanical Properties. ACS OMEGA 2023; 8:24865-24874. [PMID: 37483245 PMCID: PMC10357429 DOI: 10.1021/acsomega.3c00874] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/10/2023] [Accepted: 06/26/2023] [Indexed: 07/25/2023]
Abstract
The search for load-bearing, impact-resistant, and energy-absorbing cellular materials is of central interest in many fields including aerospace, automotive, civil, sports, packaging, and biomedical. In order to achieve the desired characteristic geometry and/or topology, a perspective approach may be used, such as utilization of atomic models as input data for 3D printing of macroscopic objects. In this paper, we suggest a new approach for the development of advanced cellular materials-crystallomorphic design based on selection of perspective crystal structures and modeling of their electron density distribution and utilization of isoelectronic surfaces as a generatrix for 3D-printed cellular materials. The ATLAS database, containing more than 10 million existing and predicted zeolites, was used as a source of data. Herein, we introduced a high-throughput screening of a data array of crystalline compounds. Several perspective designs were identified, implemented by 3D printing, and showed high characteristics. A linear correlation was found between the strength of the samples and the minimum angle and minimum bond length in the simplified crystal structures. A new cellular geometry with reinforcement struts and increased strength was discovered. This property was found by us independent of the other works, in which the cellular structures were developed by an explicit method. Thus, the developed approach holds perspective for the design of new cellular structures with increased characteristics and for the prediction of their properties.
Collapse
Affiliation(s)
- Maxim Yu. Arsentev
- Institute
of Silicate Chemistry, Russian Academy of Sciences, St. Petersburg 199034, Russia
| | - Evgeny I. Sysoev
- Department
of Micro- and Nanoelectronics, Saint Petersburg
Electrotechnical University “LETI”, Professor Popov Str. 5, St. Petersburg 197376, Russia
| | - Alexey I. Makogon
- Institute
of Silicate Chemistry, Russian Academy of Sciences, St. Petersburg 199034, Russia
| | - Sergey V. Balabanov
- Institute
of Silicate Chemistry, Russian Academy of Sciences, St. Petersburg 199034, Russia
| | - Maxim M. Sychev
- Institute
of Silicate Chemistry, Russian Academy of Sciences, St. Petersburg 199034, Russia
| | - Mahmoud H. Hammouri
- Department
of Physics, Natural and Applied Sciences, University of Wisconsin-Green Bay, Green Bay, Wisconsin 54311, United States
| | - Vyacheslav A. Moshnikov
- Department
of Micro- and Nanoelectronics, Saint Petersburg
Electrotechnical University “LETI”, Professor Popov Str. 5, St. Petersburg 197376, Russia
| |
Collapse
|
3
|
Mukherjee S, Dhara S, Saha P. Design and Additive Manufacturing of Acetabular Implant with Continuously Graded Porosity. Bioengineering (Basel) 2023; 10:675. [PMID: 37370605 DOI: 10.3390/bioengineering10060675] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/23/2023] [Revised: 05/26/2023] [Accepted: 05/30/2023] [Indexed: 06/29/2023] Open
Abstract
Porous structured metallic implants are preferable as bone graft substitutes due to their faster tissue integration mediated by bone in-growth and vascularization. The porous scaffolds/implants should also mimic the graded structure of natural bone to ensure a match of mechanical properties. This article presents a method for designing a graded porous structured acetabular implant and identifies suitable parameters for manufacturing the model through additive manufacturing. The design method is based on slice-wise modification to ensure continuity of gradation. Modification of the slices was achieved through the binary image processing route. A geodesic dome-type design was adopted for developing the acetabular cup model from the graded porous structure. The model had a solid shell with the target porosity and pore size gradually changing from 65% and 950 µm, respectively, in the inner side to 75% and 650 µm, respectively, towards the periphery. The required dimensions of the unit structures and the combinations of pore structure and strut diameter necessary to obtain the target porosity and pore size were determined analytically. Suitable process parameters were identified to manufacture the model by Direct Metal Laser Sintering (DMLS) using Ti6Al4V powder after carrying out a detailed experimental study to minimize the variation of surface roughness and warping over different build angles of the strut structures. Dual-contour scanning was implemented to simplify the scan strategy. The minimum diameter of struts that could be manufactured using the selected scanning strategy and scanning parameters was found to be 375 µm. Finally, the model was built and from the micro-CT data, the porosities and pore sizes were found to be closely conforming to the designed values. The stiffness of the structures, as found from compression testing, was also found to match with that of human trabecular bone well. Further, the structure exhibited compliant bending-dominated behaviour under compressive loading.
Collapse
Affiliation(s)
- Sumanta Mukherjee
- Production Engineering Department, BIT Sindri, Dhanbad 828123, India
| | - Santanu Dhara
- School of Medical Science and Technology, Indian Institute of Technology, Kharagpur 721302, India
| | - Partha Saha
- Mechanical Engineering Department, Indian Institute of Technology, Kharagpur 721302, India
| |
Collapse
|
4
|
Titanium Lattice Structures Produced via Additive Manufacturing for a Bone Scaffold: A Review. J Funct Biomater 2023; 14:jfb14030125. [PMID: 36976049 PMCID: PMC10059040 DOI: 10.3390/jfb14030125] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/09/2023] [Revised: 02/08/2023] [Accepted: 02/23/2023] [Indexed: 03/03/2023] Open
Abstract
The progress in additive manufacturing has remarkably increased the application of lattice materials in the biomedical field for the fabrication of scaffolds used as bone substitutes. Ti6Al4V alloy is widely adopted for bone implant application as it combines both biological and mechanical properties. Recent breakthroughs in biomaterials and tissue engineering have allowed the regeneration of massive bone defects, which require external intervention to be bridged. However, the repair of such critical bone defects remains a challenge. The present review collected the most significant findings in the literature of the last ten years on Ti6Al4V porous scaffolds to provide a comprehensive summary of the mechanical and morphological requirements for the osteointegration process. Particular attention was given on the effects of pore size, surface roughness and the elastic modulus on bone scaffold performances. The application of the Gibson–Ashby model allowed for a comparison of the mechanical performance of the lattice materials with that of human bone. This allows for an evaluation of the suitability of different lattice materials for biomedical applications.
Collapse
|
5
|
Shen M, Li Y, Lu F, Gou Y, Zhong C, He S, Zhao C, Yang G, Zhang L, Yang X, Gou Z, Xu S. Bioceramic scaffolds with triply periodic minimal surface architectures guide early-stage bone regeneration. Bioact Mater 2023; 25:374-386. [PMID: 36865987 PMCID: PMC9972395 DOI: 10.1016/j.bioactmat.2023.02.012] [Citation(s) in RCA: 5] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/19/2022] [Revised: 01/18/2023] [Accepted: 02/13/2023] [Indexed: 02/19/2023] Open
Abstract
The pore architecture of porous scaffolds is a critical factor in osteogenesis, but it is a challenge to precisely configure strut-based scaffolds because of the inevitable filament corner and pore geometry deformation. This study provides a pore architecture tailoring strategy in which a series of Mg-doped wollastonite scaffolds with fully interconnected pore networks and curved pore architectures called triply periodic minimal surfaces (TPMS), which are similar to cancellous bone, are fabricated by a digital light processing technique. The sheet-TPMS pore geometries (s-Diamond, s-Gyroid) contribute to a 3‒4-fold higher initial compressive strength and 20%-40% faster Mg-ion-release rate compared to the other-TPMS scaffolds, including Diamond, Gyroid, and the Schoen's I-graph-Wrapped Package (IWP) in vitro. However, we found that Gyroid and Diamond pore scaffolds can significantly induce osteogenic differentiation of bone marrow mesenchymal stem cells (BMSCs). Analyses of rabbit experiments in vivo show that the regeneration of bone tissue in the sheet-TPMS pore geometry is delayed; on the other hand, Diamond and Gyroid pore scaffolds show notable neo-bone tissue in the center pore regions during the early stages (3-5 weeks) and the bone tissue uniformly fills the whole porous network after 7 weeks. Collectively, the design methods in this study provide an important perspective for optimizing the pore architecture design of bioceramic scaffolds to accelerate the rate of osteogenesis and promote the clinical translation of bioceramic scaffolds in the repair of bone defects.
Collapse
Affiliation(s)
- Miaoda Shen
- Department of Orthopedics, The First Affiliated Hospital, Zhejiang University School of Medicine, Hangzhou, 310003, China
| | - Yifan Li
- Department of Orthopedics, The First Affiliated Hospital, Zhejiang University School of Medicine, Hangzhou, 310003, China
| | - Fengling Lu
- Bio-nanomaterials and Regenerative Medicine Research Division, Zhejiang-California International Nanosystem Institute, Zhejiang University, Hangzhou, 310058, China
| | - Yahui Gou
- Zhejiang University-University of Edinburgh Institute, Zhejiang University, Haining, 314499, China
| | - Cheng Zhong
- Department of Orthopedics, The First Affiliated Hospital, Zhejiang University School of Medicine, Hangzhou, 310003, China
| | - Shukun He
- Department of Orthopedics, The First Affiliated Hospital, Zhejiang University School of Medicine, Hangzhou, 310003, China
| | - Chenchen Zhao
- Department of Orthopedics, The First Affiliated Hospital, Zhejiang University School of Medicine, Hangzhou, 310003, China
| | - Guojing Yang
- Department of Orthopaedics, The Third Hospital Affiliated to Wenzhou Medical University & Rui'an People's Hospital, Rui'an, 325200, China
| | - Lei Zhang
- Department of Orthopaedics, The First Affiliated Hospital of Wenzhou Medical University, Wenzhou, 325000, China
| | - Xianyan Yang
- Bio-nanomaterials and Regenerative Medicine Research Division, Zhejiang-California International Nanosystem Institute, Zhejiang University, Hangzhou, 310058, China
| | - Zhongru Gou
- Bio-nanomaterials and Regenerative Medicine Research Division, Zhejiang-California International Nanosystem Institute, Zhejiang University, Hangzhou, 310058, China,Corresponding author.
| | - Sanzhong Xu
- Department of Orthopedics, The First Affiliated Hospital, Zhejiang University School of Medicine, Hangzhou, 310003, China,Corresponding author.
| |
Collapse
|
6
|
Naghavi SA, Tamaddon M, Garcia-Souto P, Moazen M, Taylor S, Hua J, Liu C. A novel hybrid design and modelling of a customised graded Ti-6Al-4V porous hip implant to reduce stress-shielding: An experimental and numerical analysis. Front Bioeng Biotechnol 2023; 11:1092361. [PMID: 36777247 PMCID: PMC9910359 DOI: 10.3389/fbioe.2023.1092361] [Citation(s) in RCA: 4] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/08/2022] [Accepted: 01/10/2023] [Indexed: 01/27/2023] Open
Abstract
Stress shielding secondary to bone resorption is one of the main causes of aseptic loosening, which limits the lifespan of hip prostheses and exacerbates revision surgery rates. In order to minimise post-hip replacement stress variations, this investigation proposes a low-stiffness, porous Ti6Al4V hip prosthesis, developed through selective laser melting (SLM). The stress shielding effect and potential bone resorption properties of the porous hip implant were investigated through both in vitro quasi-physiological experimental assays, together with finite element analysis. A solid hip implant was incorporated in this investigation for contrast, as a control group. The stiffness and fatigue properties of both the solid and the porous hip implants were measured through compression tests. The safety factor of the porous hip stem under both static and dynamic loading patterns was obtained through simulation. The porous hip implant was inserted into Sawbone/PMMA cement and was loaded to 2,300 N (compression). The proposed porous hip implant demonstrated a more natural stress distribution, with reduced stress shielding (by 70%) and loss in bone mass (by 60%), when compared to a fully solid hip implant. Solid and porous hip stems had a stiffness of 2.76 kN/mm and 2.15 kN/mm respectively. Considering all daily activities, the porous hip stem had a factor of safety greater than 2. At the 2,300 N load, maximum von Mises stresses on the hip stem were observed as 112 MPa on the medial neck and 290 MPa on the distal restriction point, whereby such values remained below the endurance limit of 3D printed Ti6Al4V (375 MPa). Overall, through the strut thickness optimisation process for a Ti6Al4V porous hip stem, stress shielding and bone resorption can be reduced, therefore proposing a potential replacement for the generic solid implant.
Collapse
Affiliation(s)
- Seyed Ataollah Naghavi
- Institute of Orthopaedics and Musculoskeletal Science, Division of Surgery and Interventional Science, Royal National Orthopaedic Hospital, University College London, Stanmore, United Kingdom
| | - Maryam Tamaddon
- Institute of Orthopaedics and Musculoskeletal Science, Division of Surgery and Interventional Science, Royal National Orthopaedic Hospital, University College London, Stanmore, United Kingdom
| | - Pilar Garcia-Souto
- Medical Physics and Biomedical Engineering, University College London, London, United Kingdom
| | - Mehran Moazen
- Department of Mechanical Engineering, University College London, London, United Kingdom
| | - Stephen Taylor
- Institute of Orthopaedics and Musculoskeletal Science, Division of Surgery and Interventional Science, Royal National Orthopaedic Hospital, University College London, Stanmore, United Kingdom
| | - Jia Hua
- School of Science and Technology, Middlesex University, London, United Kingdom
| | - Chaozong Liu
- Institute of Orthopaedics and Musculoskeletal Science, Division of Surgery and Interventional Science, Royal National Orthopaedic Hospital, University College London, Stanmore, United Kingdom,*Correspondence: Chaozong Liu,
| |
Collapse
|
7
|
Naghavi SA, Lin C, Sun C, Tamaddon M, Basiouny M, Garcia-Souto P, Taylor S, Hua J, Li D, Wang L, Liu C. Stress Shielding and Bone Resorption of Press-Fit Polyether-Ether-Ketone (PEEK) Hip Prosthesis: A Sawbone Model Study. Polymers (Basel) 2022; 14:4600. [PMID: 36365594 PMCID: PMC9657056 DOI: 10.3390/polym14214600] [Citation(s) in RCA: 15] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/26/2022] [Revised: 10/22/2022] [Accepted: 10/25/2022] [Indexed: 09/23/2023] Open
Abstract
Stress shielding secondary to bone resorption is one of the main causes of aseptic loosening, which limits the lifespan of the hip prostheses and increases the rates of revision surgery. This study proposes a low stiffness polyether-ether-ketone (PEEK) hip prostheses, produced by fused deposition modelling to minimize the stress difference after the hip replacement. The stress shielding effect and the potential bone resorption of the PEEK implant was investigated through both experimental tests and FE simulation. A generic Ti6Al4V implant was incorporated in this study to allow fair comparison as control group. Attributed to the low stiffness, the proposed PEEK implant showed a more natural stress distribution, less stress shielding (by 104%), and loss in bone mass (by 72%) compared with the Ti6Al4V implant. The stiffness of the Ti6Al4V and the PEEK implant were measured through compression tests to be 2.76 kN/mm and 0.276 kN/mm. The factor of safety for the PEEK implant in both static and dynamic loading scenarios were obtained through simulation. Most of the regions in the PEEK implant were tested to be safe (FoS larger than 1) in terms of representing daily activities (2300 N), while the medial neck and distal restriction point of the implant attracts large von Mises stress 82 MPa and 76 MPa, respectively, and, thus, may possibly fail during intensive activities by yield and fatigue. Overall, considering the reduction in stress shielding and bone resorption in cortical bone, PEEK could be a promising material for the patient-specific femoral implants.
Collapse
Affiliation(s)
- Seyed Ataollah Naghavi
- Institute of Orthopaedics & Musculoskeletal Science, Division of Surgery & Interventional Science, University College London, Royal National Orthopaedic Hospital, Stanmore, London HA7 4LP, UK
| | - Churun Lin
- Department of Mechanical Engineering, University College London, London WC1E 7JE, UK
| | - Changning Sun
- Institute of Orthopaedics & Musculoskeletal Science, Division of Surgery & Interventional Science, University College London, Royal National Orthopaedic Hospital, Stanmore, London HA7 4LP, UK
- State Key Laboratory for Manufacturing Systems Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, China
- National Medical Products Administration (NMPA), Key Laboratory for Research and Evaluation of Additive Manufacturing Medical Devices, Xi’an Jiaotong University, Xi’an 710054, China
| | - Maryam Tamaddon
- Institute of Orthopaedics & Musculoskeletal Science, Division of Surgery & Interventional Science, University College London, Royal National Orthopaedic Hospital, Stanmore, London HA7 4LP, UK
| | - Mariam Basiouny
- Institute of Orthopaedics & Musculoskeletal Science, Division of Surgery & Interventional Science, University College London, Royal National Orthopaedic Hospital, Stanmore, London HA7 4LP, UK
| | - Pilar Garcia-Souto
- Medical Physics & Biomedical Engineering, University College London, London WC1E 6BT, UK
| | - Stephen Taylor
- Institute of Orthopaedics & Musculoskeletal Science, Division of Surgery & Interventional Science, University College London, Royal National Orthopaedic Hospital, Stanmore, London HA7 4LP, UK
| | - Jia Hua
- School of Science and Technology, Middlesex University, London NW4 4BT, UK
| | - Dichen Li
- State Key Laboratory for Manufacturing Systems Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, China
- National Medical Products Administration (NMPA), Key Laboratory for Research and Evaluation of Additive Manufacturing Medical Devices, Xi’an Jiaotong University, Xi’an 710054, China
| | - Ling Wang
- State Key Laboratory for Manufacturing Systems Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, China
- National Medical Products Administration (NMPA), Key Laboratory for Research and Evaluation of Additive Manufacturing Medical Devices, Xi’an Jiaotong University, Xi’an 710054, China
| | - Chaozong Liu
- Institute of Orthopaedics & Musculoskeletal Science, Division of Surgery & Interventional Science, University College London, Royal National Orthopaedic Hospital, Stanmore, London HA7 4LP, UK
| |
Collapse
|