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Igarashi M, Ohkuma K. Development of lightweight and high-strength hollow titanium-plated denture material using three-dimensional printing. Odontology 2024; 112:1157-1166. [PMID: 38523208 DOI: 10.1007/s10266-024-00923-3] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/04/2023] [Accepted: 02/21/2024] [Indexed: 03/26/2024]
Abstract
Owing to its desirable ability to fabricate complex shapes, three-dimensional printing is preferred over casting for manufacturing dentures. Furthermore, titanium is widely used in dental implants and dentures because of its high corrosion resistance, biocompatibility, strength, and low density. In this study, we aimed to develop a new metal denture material from three-dimensional-printed (3DP) to achieve lighter weight and greater strength than those of PMMA dentures. Hollow (3DP-H) structure and solid (3DP-S) structure titanium plate specimens of 0.5, 1.0, and 3.0 mm in thickness were used. Casted Ti, casted Co-Cr, and PMMA plates were fabricated for comparison. Elastic modulus, density, thermal conductivity, hardness, and proof stress of the specimens were measured and plotted on a radar chart to enable multifaceted evaluation. The results indicated that the density of the 3DP-H plates reduced by 28-36% compared with those of 3DP-S and cast Ti plates. The weight of the metal-denture-equivalent section of the 0.5-mm-thick 3DP-H titanium-plated denture reduced to two-thirds that of the 2.0-mm-thick PMMA denture. The proof stress of the 0.5-mm-thick 3DP-H plate increased to about 3 times that of the 2.0-mm-thick PMMA plate. The total value of the 0.5-mm-thick 3DP-H titanium plates was higher than it of the 1.0-mm-thick PMMA plates. This study suggests that it is possible to produce 3DP-H titanium plate dentures exhibiting not only extremely lightweight compared to conventional PMMA dentures but also sufficient strength.
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Affiliation(s)
- Masahiro Igarashi
- Course of Applied Science, Field of Developmental Science of Oral Biomaterials, The Nippon Dental University Graduate School of Life Dentistry at Niigata, 1-8 Hamaura-cho, Chuo-ku, Niigata City, Niigata, 951-8580, Japan.
| | - Kazuo Ohkuma
- Course of Applied Science, Field of Developmental Science of Oral Biomaterials, The Nippon Dental University Graduate School of Life Dentistry at Niigata, 1-8 Hamaura-cho, Chuo-ku, Niigata City, Niigata, 951-8580, Japan
- Department of Dental Materials Science, The Nippon Dental University School of Life Dentistry at Niigata, 1-8 Hamaura-cho, Chuo-ku, Niigata City, Niigata, 951-8580, Japan
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2
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O'Keeffe C, Kotlarz M, Gonçalves IF, Lally C, Kelly DJ. Chemical etching of Ti-6Al-4V biomaterials fabricated by selective laser melting enhances mesenchymal stromal cell mineralization. J Biomed Mater Res A 2024; 112:1548-1564. [PMID: 38515311 DOI: 10.1002/jbm.a.37709] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/04/2023] [Revised: 03/05/2024] [Accepted: 03/09/2024] [Indexed: 03/23/2024]
Abstract
Porous titanium scaffolds fabricated by powder bed fusion additive manufacturing techniques have been widely adopted for orthopedic and bone tissue engineering applications. Despite the many advantages of this approach, topological defects inherited from the fabrication process are well understood to negatively affect mechanical properties and pose a high risk if dislodged after implantation. Consequently, there is a need for further post-process surface cleaning. Traditional techniques such as grinding or polishing are not suited to lattice structures, due to lack of a line of sight to internal features. Chemical etching is a promising alternative; however, it remains unclear if changes to surface properties associated with such protocols will influence how cells respond to the material surface. In this study, we explored the response of bone marrow derived mesenchymal stem/stromal cells (MSCs) to Ti-6Al-4V whose surface was exposed to different durations of chemical etching. Cell morphology was influenced by local topological features inherited from the SLM fabrication process. On the as-built surface, topological nonhomogeneities such as partially adhered powder drove a stretched anisotropic cellular morphology, with large areas of the cell suspended across the nonhomogeneous powder interface. As the etching process was continued, surface defects were gradually removed, and cell morphology appeared more isotropic and was suggestive of MSC differentiation along an osteoblastic-lineage. This was accompanied by more extensive mineralization, indicative of progression along an osteogenic pathway. These findings point to the benefit of post-process chemical etching of additively manufactured Ti-6Al-4V biomaterials targeting orthopedic applications.
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Affiliation(s)
- Conor O'Keeffe
- Trinity Centre for Biomedical Engineering, Trinity Biomedical Sciences Institute, Trinity College Dublin, Dublin, Ireland
- Department of Mechanical, Manufacturing and Biomedical Engineering, School of Engineering, Trinity College Dublin, Dublin, Ireland
- AMBER, the SFI Research Centre for Advanced Materials and Bioengineering Research, Ireland
| | - Marcin Kotlarz
- Trinity Centre for Biomedical Engineering, Trinity Biomedical Sciences Institute, Trinity College Dublin, Dublin, Ireland
- Department of Mechanical, Manufacturing and Biomedical Engineering, School of Engineering, Trinity College Dublin, Dublin, Ireland
- AMBER, the SFI Research Centre for Advanced Materials and Bioengineering Research, Ireland
| | - Inês F Gonçalves
- Trinity Centre for Biomedical Engineering, Trinity Biomedical Sciences Institute, Trinity College Dublin, Dublin, Ireland
- Department of Mechanical, Manufacturing and Biomedical Engineering, School of Engineering, Trinity College Dublin, Dublin, Ireland
- AMBER, the SFI Research Centre for Advanced Materials and Bioengineering Research, Ireland
| | - Caitríona Lally
- Trinity Centre for Biomedical Engineering, Trinity Biomedical Sciences Institute, Trinity College Dublin, Dublin, Ireland
- Department of Mechanical, Manufacturing and Biomedical Engineering, School of Engineering, Trinity College Dublin, Dublin, Ireland
- AMBER, the SFI Research Centre for Advanced Materials and Bioengineering Research, Ireland
- Department of Anatomy and Regenerative Medicine, Royal College of Surgeons in Ireland, Dublin, Ireland
| | - Daniel J Kelly
- Trinity Centre for Biomedical Engineering, Trinity Biomedical Sciences Institute, Trinity College Dublin, Dublin, Ireland
- Department of Mechanical, Manufacturing and Biomedical Engineering, School of Engineering, Trinity College Dublin, Dublin, Ireland
- AMBER, the SFI Research Centre for Advanced Materials and Bioengineering Research, Ireland
- Department of Anatomy and Regenerative Medicine, Royal College of Surgeons in Ireland, Dublin, Ireland
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3
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Nicum A, Di Laura A, Hothi H, Henckel J, Schlueter-Brust K, Hart A. Surface adhered titanium particles on 3D printed off-the-shelf acetabular cups. J Orthop Res 2024. [PMID: 39171637 DOI: 10.1002/jor.25958] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Received: 05/03/2024] [Revised: 07/15/2024] [Accepted: 08/04/2024] [Indexed: 08/23/2024]
Abstract
3D printing is a rapidly growing manufacturing method of medical implants. In orthopedics, this method enables the construction of complex porous structures with the aim of improved bone fixation. A known by-product of the 3D printing process is surface adhered particles which are often challenging to remove from the strut surfaces of the porous region. This study investigates the presence of these particles in the porous region of unused 3D printed off-the-shelf acetabular cup from five manufacturers. Scanning Electron Microscopy (SEM) and image analysis software were used to determine the frequency and diameters of particles present on these implants. Surface adhered particles were found in the porous structures of all implants with some exhibiting more particles at the subsurface level than the surface level. Implants manufactured via Selective Laser Melting (SLM) exhibited a higher number of surface adhered particles per mm2 at both the surface and subsurface levels than those manufactured by Electron Beam Melting (EBM). Additionally, and consistent with previous literature, the particle diameter of the SLM cups was found to be smaller than those on the EBM cups, as well as having a visually lower level of adherence which could raise concern about the likelihood of breakage of these particles in-vivo.
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Affiliation(s)
- Arya Nicum
- The Institute of Orthopaedics and Musculoskeletal Science, University College London, London, Stanmore, UK
| | - Anna Di Laura
- The Royal National Orthopaedic Hospital NHS Trust, Stanmore, UK
- The Department of Mechanical Engineering, University College London, London, Stanmore, UK
| | - Harry Hothi
- The Royal National Orthopaedic Hospital NHS Trust, Stanmore, UK
- The Department of Mechanical Engineering, University College London, London, Stanmore, UK
| | - Johann Henckel
- The Royal National Orthopaedic Hospital NHS Trust, Stanmore, UK
| | | | - Alister Hart
- The Institute of Orthopaedics and Musculoskeletal Science, University College London, London, Stanmore, UK
- The Royal National Orthopaedic Hospital NHS Trust, Stanmore, UK
- Cleveland Clinic London, London, Stanmore, UK
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4
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Sharma V, Barua R. Synthesis, Characterization, and Magnetocaloric Properties of the Ternary Boride Fe 2AlB 2 for Caloric Applications. MATERIALS (BASEL, SWITZERLAND) 2024; 17:3886. [PMID: 39203064 PMCID: PMC11355234 DOI: 10.3390/ma17163886] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 06/30/2024] [Revised: 07/29/2024] [Accepted: 08/02/2024] [Indexed: 09/03/2024]
Abstract
The ternary transition metal boride Fe2AlB2 is a unique ferromagnetic "MAB" phase that demonstrates a sizable magnetocaloric effect near room temperature-a feature that renders this material suitable for magnetic heat pump devices (MHP), a promising alternative to conventional vapor compression technology. Here, we provide a comprehensive review of the material properties of Fe2AlB2 (magnetofunctional response, transport properties, and mechanical stability) and discuss alloy synthesis from the perspective of shaping these materials as porous active magnetic regenerators in MHPs. Salient aspects of the coupled magnetic and structural phase transitions are critically assessed to elucidate the fundamental origin of the functional response. The goal is to provide insight into strategies to tune the magnetofunctional response via elemental substitution and microstructure optimization. Finally, outstanding challenges that reduce the commercial viability of Fe2AlB2 are discussed, and opportunities for further developments in this field are identified.
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Affiliation(s)
| | - Radhika Barua
- Department of Mechanical & Nuclear Engineering, Virginia Commonwealth University, 401 West Main Street, Richmond, VA 23284, USA;
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Chen J, Chen B. Progress in Additive Manufacturing of Magnesium Alloys: A Review. MATERIALS (BASEL, SWITZERLAND) 2024; 17:3851. [PMID: 39124514 PMCID: PMC11314001 DOI: 10.3390/ma17153851] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/03/2024] [Revised: 07/12/2024] [Accepted: 07/23/2024] [Indexed: 08/12/2024]
Abstract
Magnesium alloys, renowned for their lightweight yet high-strength characteristics, with exceptional mechanical properties, are highly coveted for numerous applications. The emergence of magnesium alloy additive manufacturing (Mg AM) has further propelled their popularity, offering advantages such as unparalleled precision, swift production rates, enhanced design freedom, and optimized material utilization. This technology holds immense potential in fabricating intricate geometries, complex internal structures, and performance-tailored microstructures, enabling groundbreaking applications. In this paper, we delve into the core processes and pivotal influencing factors of the current techniques employed in Mg AM, including selective laser melting (SLM), electron beam melting (EBM), wire arc additive manufacturing (WAAM), binder jetting (BJ), friction stir additive manufacturing (FSAM), and indirect additive manufacturing (I-AM). Laser powder bed fusion (LPBF) excels in precision but is limited by a low deposition rate and chamber size; WAAM offers cost-effectiveness, high efficiency, and scalability for large components; BJ enables precise material deposition for customized parts with environmental benefits; FSAM achieves fine grain sizes, low defect rates, and potential for precision products; and I-AM boasts a high build rate and industrial adaptability but is less studied recently. This paper attempts to explore the possibilities and challenges for future research in AM. Among them, two issues are how to mix different AM applications and how to use the integration of Internet technologies, machine learning, and process modeling with AM, which are innovative breakthroughs in AM.
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Affiliation(s)
| | - Bin Chen
- School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China;
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Singh N, Srikanth KP, Gopal V, Rajput M, Manivasagam G, Prashanth KG, Chatterjee K, Suwas S. In situ production of low-modulus Ti-Nb alloys by selective laser melting and their functional assessment toward orthopedic applications. J Mater Chem B 2024; 12:5982-5993. [PMID: 38809161 DOI: 10.1039/d4tb00379a] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 05/30/2024]
Abstract
This work aimed to manufacture Ti-28.5Nb and Ti-40.0Nb (wt%) alloys in situ via selective laser melting (SLM) from Ti and Nb elemental powders. X-ray diffraction analysis revealed complete β-phase (cubic) in Ti-40.0Nb and a mixture of (α'' orthorhombic + β cubic) phases in Ti-28.5Nb were formed, whereas few of the Nb particles remained only partially fused during manufacturing. The fraction of partially melted Nb particles was determined as ∼2 and ∼18% in Ti-28.5Nb and Ti-40Nb, respectively. Mechanical characterization revealed higher hardness and more strength in Ti-28.5Nb than in Ti-40.0Nb due to the presence of the α'' phase in the former. Tribocorrosion tests reveal a significantly better wear-corrosion resistance for Ti-40.0Nb, as determined from a lower total volume loss in Ti-40.0Nb (∼2 × 10-4 mm-3) than in Ti-28.5Nb (∼13 × 10-2 mm-3). The lower volume loss and better corrosion resistance behavior are attributed to the β phase, which was dominant in Ti-40.0Nb. Cell studies reveal no toxicity for up to 7 days. Both the alloys were better at supporting cell proliferation than wrought Ti6Al4V. This study presents a route to preparing Ti-Nb alloys in situ by SLM that are promising candidates for biomedical applications.
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Affiliation(s)
- Neera Singh
- Department of Materials Engineering, Indian Institute of Science, Bangalore 560012, India.
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, Estonia
| | - K P Srikanth
- Department of Materials Engineering, Indian Institute of Science, Bangalore 560012, India.
| | - Vasanth Gopal
- Department of Physics, School of Advanced Sciences, Vellore Institute of Technology, Vellore 632014, India
| | - Monika Rajput
- Department of Materials Engineering, Indian Institute of Science, Bangalore 560012, India.
| | - Geetha Manivasagam
- Department of Physics, School of Advanced Sciences, Vellore Institute of Technology, Vellore 632014, India
- CBCMT, School of Mechanical Engineering, Vellore Institute of Technology, Vellore 632014, India
| | - K G Prashanth
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, Estonia
- CBCMT, School of Mechanical Engineering, Vellore Institute of Technology, Vellore 632014, India
| | - Kaushik Chatterjee
- Department of Materials Engineering, Indian Institute of Science, Bangalore 560012, India.
| | - Satyam Suwas
- Department of Materials Engineering, Indian Institute of Science, Bangalore 560012, India.
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7
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Bernard AR, ElSayed MSA. Design, Manufacturing, and Analysis of Periodic Three-Dimensional Cellular Materials for Energy Absorption Applications: A Critical Review. MATERIALS (BASEL, SWITZERLAND) 2024; 17:2181. [PMID: 38793248 PMCID: PMC11122817 DOI: 10.3390/ma17102181] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/07/2024] [Revised: 04/19/2024] [Accepted: 04/24/2024] [Indexed: 05/26/2024]
Abstract
Cellular materials offer industries the ability to close gaps in the material selection design space with properties not otherwise achievable by bulk, monolithic counterparts. Their superior specific strength, stiffness, and energy absorption, as well as their multi-functionality, makes them desirable for a wide range of applications. The objective of this paper is to compile and present a review of the open literature focusing on the energy absorption of periodic three-dimensional cellular materials. The review begins with the methodical cataloging of qualitative and quantitative elements from 100 papers in the available literature and then provides readers with a thorough overview of the state of this research field, discussing areas such as parent material(s), manufacturing methods, cell topologies, cross-section shapes for truss topologies, analysis methods, loading types, and test strain rates. Based on these collected data, areas of great and limited research are identified and future avenues of interest are suggested for the continued maturation and growth of this field, such as the development of a consistent naming and classification system for topologies; the creation of test standards considering additive manufacturing processes; further investigation of non-uniform and non-cylindrical struts on the performance of truss lattices; and further investigation into the performance of lattice materials under the impact of non-flat surfaces and projectiles. Finally, the numerical energy absorption (by mass and by volume) data of 76 papers are presented across multiple property selection charts, highlighting various materials, manufacturing methods, and topology groups. While there are noticeable differences at certain densities, the graphs show that the categorical differences within those groups have large overlap in terms of energy absorption performance and can be referenced to identify areas for further investigation and to help in the preliminary design process by researchers and industry professionals alike.
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Affiliation(s)
| | - Mostafa S. A. ElSayed
- Mechanical and Aerospace Engineering, Carleton University, Ottawa, ON K1S 5B6, Canada
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Choudhari A, Elder J, Mugale M, Karki S, Digole S, Omeike S, Borkar T. Enhancing Quality Control: Image-Based Quantification of Carbides and Defect Remediation in Binder Jetting Additive Manufacturing. MATERIALS (BASEL, SWITZERLAND) 2024; 17:2174. [PMID: 38793241 PMCID: PMC11123299 DOI: 10.3390/ma17102174] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/10/2024] [Revised: 04/29/2024] [Accepted: 05/02/2024] [Indexed: 05/26/2024]
Abstract
While binder jetting (BJ) additive manufacturing (AM) holds considerable promise for industrial applications, defects often compromise part quality. This study addresses these challenges by investigating binding mechanisms and analyzing common defects, proposing tailored solutions to mitigate them. Emphasizing defect identification for effective quality control in BJ-AM, this research offers strategies for in-process rectification and post-process evaluation to elevate part quality. It shows how to successfully process metallic parts with complex geometries while maintaining consistent material properties. Furthermore, the paper explores the microstructure of AISI M2 tool steel, utilizing advanced image processing techniques like digital image analysis and SEM images to evaluate carbide distribution. The results show that M2 tool steel has a high proportion of M6C carbides, with furnace-cooled samples ranging from ~2.4% to 7.1% and MC carbides from ~0.4% to 9.4%. M6C carbides ranged from ~2.6% to 3.8% in air-cooled samples, while water-cooled samples peaked at ~8.52%. Sintering conditions also affected shrinkage, with furnace-cooled samples showing the lowest rates (1.7 ± 0.4% to 5 ± 0.4%) and water-cooled samples showing the highest (2 ± 0.4% to 14.1 ± 0.4%). The study recommends real-time defect detection systems with autonomous corrective capabilities to improve the quality and performance of BJ-AM components.
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Affiliation(s)
| | | | | | | | | | | | - Tushar Borkar
- Department of Mechanical Engineering, Washkewicz College of Engineering Cleveland State University, Cleveland, OH 44115, USA
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Garcia GES, de Sousa Junior RR, Gouveia JR, dos Santos DJ. Graphene Oxide-Based Nanocomposites for Stereolithography (SLA) 3D Printing: Comprehensive Mechanical Characterization under Combined Loading Modes. Polymers (Basel) 2024; 16:1261. [PMID: 38732730 PMCID: PMC11085675 DOI: 10.3390/polym16091261] [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: 04/08/2024] [Revised: 04/29/2024] [Accepted: 04/29/2024] [Indexed: 05/13/2024] Open
Abstract
Additive manufacturing, particularly Stereolithography (SLA), has gained widespread attention thanks to its ability to produce intricate parts with high precision and customization capacity. Nevertheless, the inherent low mechanical properties of SLA-printed parts limit their use in high-value applications. One approach to enhance these properties involves the incorporation of nanomaterials, with graphene oxide (GO) being a widely studied option. However, the characterization of SLA-printed GO nanocomposites under various stress loadings remains underexplored in the literature, despite being essential for evaluating their mechanical performance in applications. This study aimed to address this gap by synthesizing GO and incorporating it into a commercial SLA resin at different concentrations (0.2, 0.5, and 1 wt.%). Printed specimens were subjected to pure tension, combined stresses, and pure shear stress modes for comprehensive mechanical characterization. Additionally, failure criteria were provided using the Drucker--Prager model.
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Affiliation(s)
| | - Rogerio Ramos de Sousa Junior
- Center for Engineering, Modeling and Applied Social Sciences, Federal University of ABC, Santo André 09210-580, Brazil; (G.E.S.G.); (J.R.G.)
| | | | - Demetrio Jackson dos Santos
- Center for Engineering, Modeling and Applied Social Sciences, Federal University of ABC, Santo André 09210-580, Brazil; (G.E.S.G.); (J.R.G.)
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Yakubov V, Ostergaard H, Bhagavath S, Leung CLA, Hughes J, Yasa E, Khezri M, Löschke SK, Li Q, Paradowska AM. Recycled aluminium feedstock in metal additive manufacturing: A state of the art review. Heliyon 2024; 10:e27243. [PMID: 38463898 PMCID: PMC10923728 DOI: 10.1016/j.heliyon.2024.e27243] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/22/2023] [Revised: 02/17/2024] [Accepted: 02/27/2024] [Indexed: 03/12/2024] Open
Abstract
Additive manufacturing has revolutionised the production of functional components and assemblies, offering a high degree of manufacturing flexibility. This review explores the latest advancements in additive manufacturing, focusing on its fusion-based and solid-state based technologies, and highlights the use of recycled aluminium as feedstock in these processes. The advantages and limitations of incorporating recycled materials are thoroughly analysed, considering factors such as material properties, sustainability, and process acceptance. While up to 14.4 kg CO2 per kg of aluminium is released during primary aluminium ingot production, solid-state based additive manufacturing, which is tolerant of feedstock contamination, can directly recycle aluminium. Meanwhile, fusion based additive manufacturing can readily utilise recycling pathways such as maintaining grade, upcycling, and downcycling, as well as powder reuse, providing opportunities for significant emissions reduction. The examination of feedstock manufacturing in this review, such as wire for WAAM and powder for PBF, indicates that this step indirectly increases the resource consumption of additive manufacturing. Finally, the alignment of aluminium recycling and additive manufacturing with Circular Economy principles and the UN's sustainable development goals are addressed, highlighting contributions to SDGs 3, 9, and 12.
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Affiliation(s)
- Vladislav Yakubov
- School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia
| | - Halsey Ostergaard
- School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia
- Australian Nuclear Science and Technology Organisation, Kirrawee, NSW, Australia
| | - Shishira Bhagavath
- Department of Mechanical Engineering, University College London, London, UK
| | - Chu Lun Alex Leung
- Department of Mechanical Engineering, University College London, London, UK
- The Research Complex at Harwell, Harwell Campus, Oxfordshire, UK
| | - James Hughes
- University of Sheffield, Advanced Manufacturing Research Centre (AMRC), Sheffield, UK
| | - Evren Yasa
- University of Sheffield, Advanced Manufacturing Research Centre (AMRC), Sheffield, UK
| | - Mani Khezri
- School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia
| | - Sandra K. Löschke
- Sydney School of Architecture, Design and Planning, The University of Sydney, Sydney, NSW, Australia
| | - Qing Li
- School of Aerospace, Mechanical and Mechatronic Engineering, The University of Sydney, Sydney, NSW, Australia
| | - Anna M. Paradowska
- School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia
- Australian Nuclear Science and Technology Organisation, Kirrawee, NSW, Australia
- School of Aerospace, Mechanical and Mechatronic Engineering, The University of Sydney, Sydney, NSW, Australia
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11
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Raza SA, Canyurt OE, Sezer HK. A systematic review of Inconel 939 alloy parts development via additive manufacturing process. Heliyon 2024; 10:e25506. [PMID: 38352740 PMCID: PMC10862689 DOI: 10.1016/j.heliyon.2024.e25506] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/17/2023] [Revised: 01/22/2024] [Accepted: 01/29/2024] [Indexed: 02/16/2024] Open
Abstract
IN939 is a modern class of nickel-based superalloys designed for continuous operational sustenance at elevated temperatures owing to their excellent combination of fatigue, creep, and corrosion resistance. This unique performance of IN939 is associated with the composition of this alloy, along with specific post-processing treatments such as solution treatment and aging, giving rise to features such as the presence of γ' residues, as well as the presence of MC and M23C6 carbides. This also includes the absence of the eutectic and incipient melting phases. For this alloy, the primary part development is by the powder bed fusion process using a laser powder bed fusion machine. At the same time, a solo study highlights the use of an EB-PBF machine for the synthesis. The AM development process of these alloys is hindered by machine parameters, which have been found ineffective in isolation to obtain a fully dense structure with desired properties. The purpose of these parameters is to improve their core properties while minimizing defects associated with powder metallurgy routes, such as porosity, detrimental precipitates, grain anisotropy, etc. This study aims to provide an overview of the advancements in research related to IN939, explicitly focusing on the benchmarks achieved through additive manufacturing techniques. We have discussed the work performed in this area, compared the results of different studies, and identified the gaps in current research. By doing so, we aim to provide a comprehensive understanding of the potential of IN939 and its applications in extreme environments.
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Affiliation(s)
- Syed Abbas Raza
- Department of Mechanical Engineering, Faculty of Engineering, Gazi University, Eti Mah. Yukselis Sk. No: 5, 06570, Maltepe, Ankara, Turkey
- Additive Manufacturing Technologies Research and Application Center-EKTAM, Gazi University, Saray OSB Mahallesi, Uzay ve Havacılık OSB Küme Evleri, No:62 Kahramankazan, Ankara, Turkey
| | - Olcay Ersel Canyurt
- Department of Mechanical Engineering, Faculty of Engineering, Gazi University, Eti Mah. Yukselis Sk. No: 5, 06570, Maltepe, Ankara, Turkey
- Additive Manufacturing Technologies Research and Application Center-EKTAM, Gazi University, Saray OSB Mahallesi, Uzay ve Havacılık OSB Küme Evleri, No:62 Kahramankazan, Ankara, Turkey
| | - Hüseyin Kürşad Sezer
- Department of Industrial Design Engineering, Faculty of Technology, Gazi University, Emniyet Mah. Bandırma Cad. No: 6, 06560, Yenimahalle, Ankara, Turkey
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Singh S, Palani IA, Paul CP, Funk A, Konda Gokuldoss P. Wire Arc Additive Manufacturing of NiTi 4D Structures: Influence of Interlayer Delay. 3D PRINTING AND ADDITIVE MANUFACTURING 2024; 11:152-162. [PMID: 38389695 PMCID: PMC10880663 DOI: 10.1089/3dp.2021.0296] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/24/2024]
Abstract
Shape memory alloy structures for actuator and vibration damper applications may be manufactured using wire arc additive manufacturing (WAAM), which is one of the additive manufacturing technologies. Multilayer deposition causes heat accumulation during WAAM, which rises the preheat temperature of the previously created layer. This leads to process instabilities, which result in deviations from the desired dimensions and mechanical properties changes. During WAAM deposition of the wall structure, a systematic research is carried out by adjusting the interlayer delay from 10 to 30 s. When the delay period is increased from 10 to 30 s, the breadth decreases by 45% and the height increases by 33%. Grain refinement occurs when the interlayer delay duration is increased, resulting in better hardness, phase transformation temperature, compressive strength, and shape recovery behavior. This study shows how the interlayer delay affects the behavior of WAAM-built nickel-titanium alloy (NiTi) structures in a variety of applications.
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Affiliation(s)
- Shalini Singh
- Mechatronics and Instrumentation Lab, Department of Mechanical Engineering, Indian Institute of Technology Indore, Indore, India
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology, Tallinn, Estonia
| | - Iyamperumal Anand Palani
- Mechatronics and Instrumentation Lab, Department of Mechanical Engineering, Indian Institute of Technology Indore, Indore, India
| | - Christ Prakash Paul
- Laser Technology Division, Raja Ramanna Centre for Advanced Technology, Indore, India
- Homi Bhabha National Institute, Anushaktinagar, Mumbai, India
| | - Alexander Funk
- Bundesanstalt für Materialforschung und-prüfung (BAM), Berlin, Germany
| | - Prashanth Konda Gokuldoss
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology, Tallinn, Estonia
- Erich Schmid Institute of Materials Science, Austrian Academy of Sciences, Leoben, Austria
- CBCMT, Vellore Institute of Technology, Vellore, India
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13
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Wang Z, Ushakov IV, Safronov IS, Zuo J. Physical Mechanism of Selective Healing of Nanopores in Condensed Matter under the Influence of Laser Irradiation and Plasma. NANOMATERIALS (BASEL, SWITZERLAND) 2024; 14:139. [PMID: 38251104 PMCID: PMC10820897 DOI: 10.3390/nano14020139] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/27/2023] [Revised: 12/29/2023] [Accepted: 01/03/2024] [Indexed: 01/23/2024]
Abstract
The investigation of the features of laser control over the state of nanoscale objects in solid materials is an urgent task of condensed matter physics. We experimentally established the potential for the simultaneous enhancement of hardness and resistance to surface cracking in a titanium alloy due to selective laser irradiation. The regularities of selective heating near nanopores and the influence of the nanopore system on the features of isotherm propagation have been revealed. A physical model is proposed for the healing of nanopores situated in the surface layer of the sample. According to this model and as a result of laser irradiation and laser plasma, a brief transition of the material surface to extreme conditions is initiated.
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Affiliation(s)
- Zhiqiang Wang
- School of Energy and Mining Engineering, China University of Mining and Technology (Beijing), Beijing 100083, China;
| | | | - Ivan Sergeevich Safronov
- Physics Department, National University of Science and Technology “MISIS”, 119049 Moscow, Russia;
| | - Jianping Zuo
- School of Mechanics and Civil Engineering, China University of Mining and Technology (Beijing), Beijing 100083, China
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14
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Venkatesan K, Tchekep AGK, Anadebe VC, Mathew AM, Sreya PV, Rajendran A, Barik RC, Pattanayak DK. Development of bioactive and antimicrobial nano-topography over selective laser melted Ti6Al4V implant and its in-vitro corrosion behavior. J Mech Behav Biomed Mater 2024; 149:106210. [PMID: 37984283 DOI: 10.1016/j.jmbbm.2023.106210] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/23/2023] [Revised: 10/22/2023] [Accepted: 10/23/2023] [Indexed: 11/22/2023]
Abstract
Additive manufacturing (AM) or 3D printing of bone defect models is gaining much attention in the biomedical field as it could significantly facilitate the development of customized implants with a high degree of dimensional accuracy. Due to their satisfactory biocompatibility and minimal stress shielding effect, Ti6Al4V (Ti64) alloys are increasingly preferred in the development of such implants. However, their poor osseointegration abilities and lack of antibacterial properties often cause implant loosening and microbial infections, leading to implant failure. To address these drawbacks, we propose in this work a simple surface modification approach of customized Ti64 alloys (3D printed Ti6Al4V) that enables the formation of porous calcium titanate (CT) over their surface as well as the incorporation of silver nanoparticles (AgNPs) into the thus formed porous network. The successful CT formation with the incorporation of AgNPs throughout the 3D printed Ti64 surface and their influence in changing the morphological and mechanical behaviour were studied by Raman spectroscopy, SEM, AFM, Contact angle measurement, XPS, HR-TEM and nano-indentation. Antibacterial studies using Staphylococcus aureus and Escherichia coli, and in-vitro cell studies using MG-63 cell lines showed that surface modified samples resulting from the proposed method exhibit satisfactory antimicrobial property and are highly biocompatible. The obtained surface modified samples also showed a significant improvement in corrosion resistance as compared to unmodified 3D printed Ti64 alloys. The improvement in corrosion resistance was revealed by electrochemical impedance Spectroscopy (EIS). Obtained results emphasis that thus surface modified 3D printed Ti64 alloys are promising candidates for hard tissue implant applications.
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Affiliation(s)
- K Venkatesan
- Electrochemical Process Engineering Division, CSIR- Central Electrochemical Research Institute, Karaikudi, 630003, Tamil Nadu, India; Academy of Scientific and Innovative Research (AcSIR), Ghaziabad-201002, India
| | - A G Kamaha Tchekep
- Electrochemical Process Engineering Division, CSIR- Central Electrochemical Research Institute, Karaikudi, 630003, Tamil Nadu, India; Academy of Scientific and Innovative Research (AcSIR), Ghaziabad-201002, India
| | - Valentine Chikaodili Anadebe
- Academy of Scientific and Innovative Research (AcSIR), Ghaziabad-201002, India; Corrosion and Materials Protection Division, CSIR- Central Electrochemical Research Institute, Karaikudi, 630003, Tamil Nadu, India; Department of Chemical Engineering, Alex Ekwueme Federal University Ndufu Alike, PMB 1010, Abakaliki, Ebonyi State, Nigeria
| | - Ann Mary Mathew
- Electrochemical Process Engineering Division, CSIR- Central Electrochemical Research Institute, Karaikudi, 630003, Tamil Nadu, India; Academy of Scientific and Innovative Research (AcSIR), Ghaziabad-201002, India
| | - P V Sreya
- Electrochemical Process Engineering Division, CSIR- Central Electrochemical Research Institute, Karaikudi, 630003, Tamil Nadu, India; Academy of Scientific and Innovative Research (AcSIR), Ghaziabad-201002, India
| | - Archana Rajendran
- Electrochemical Process Engineering Division, CSIR- Central Electrochemical Research Institute, Karaikudi, 630003, Tamil Nadu, India; Academy of Scientific and Innovative Research (AcSIR), Ghaziabad-201002, India; National Centre for Cell Science, Pune, 411007, Maharashtra, India
| | - Rakesh C Barik
- Academy of Scientific and Innovative Research (AcSIR), Ghaziabad-201002, India; Corrosion and Materials Protection Division, CSIR- Central Electrochemical Research Institute, Karaikudi, 630003, Tamil Nadu, India
| | - Deepak K Pattanayak
- Electrochemical Process Engineering Division, CSIR- Central Electrochemical Research Institute, Karaikudi, 630003, Tamil Nadu, India; Academy of Scientific and Innovative Research (AcSIR), Ghaziabad-201002, India.
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15
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Tebianian M, Aghaie S, Razavi Jafari NS, Elmi Hosseini SR, Pereira AB, Fernandes FAO, Farbakhti M, Chen C, Huo Y. A Review of the Metal Additive Manufacturing Processes. MATERIALS (BASEL, SWITZERLAND) 2023; 16:7514. [PMID: 38138655 PMCID: PMC10744938 DOI: 10.3390/ma16247514] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/31/2023] [Revised: 11/20/2023] [Accepted: 11/22/2023] [Indexed: 12/24/2023]
Abstract
Metal additive manufacturing (AM) is a layer-by-layer process that makes the direct manufacturing of various industrial parts possible. This method facilitates the design and fabrication of complex industrial, advanced, and fine parts that are used in different industry sectors, such as aerospace, medicine, turbines, and jewelry, where the utilization of other fabrication techniques is difficult or impossible. This method is advantageous in terms of dimensional accuracy and fabrication speed. However, the parts fabricated by this method may suffer from faults such as anisotropy, micro-porosity, and defective joints. Metals like titanium, aluminum, stainless steels, superalloys, etc., have been used-in the form of powder or wire-as feed materials in the additive manufacturing of various parts. The main criterion that distinguishes different additive manufacturing processes from each other is the deposition method. With regard to this criterion, AM processes can be divided into four classes: local melting, sintering, sheet forming, and electrochemical methods. Parameters affecting the properties of the additive-manufactured part and the defects associated with an AM process determine the method by which a certain part should be manufactured. This study is a survey of different additive manufacturing processes, their mechanisms, capabilities, shortcomings, and the general properties of the parts manufactured by them.
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Affiliation(s)
- Mohaddeseh Tebianian
- School of Metallurgy and Materials Engineering, Iran University of Science and Technology (IUST), Narmak, Tehran 13114-16846, Iran
| | - Sara Aghaie
- School of Metallurgy and Materials Engineering, Iran University of Science and Technology (IUST), Narmak, Tehran 13114-16846, Iran
| | - Nazanin Sadat Razavi Jafari
- School of Metallurgy and Materials Engineering, Iran University of Science and Technology (IUST), Narmak, Tehran 13114-16846, Iran
| | - Seyed Reza Elmi Hosseini
- School of Metallurgy and Materials Engineering, Iran University of Science and Technology (IUST), Narmak, Tehran 13114-16846, Iran
| | - António B. Pereira
- TEMA: Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, University of Aveiro, Campus de Santiago, 3810-193 Aveiro, Portugal
| | - Fábio A. O. Fernandes
- TEMA: Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, University of Aveiro, Campus de Santiago, 3810-193 Aveiro, Portugal
| | - Mojtaba Farbakhti
- School of Metallurgy and Materials Engineering, Iran University of Science and Technology (IUST), Narmak, Tehran 13114-16846, Iran
| | - Chao Chen
- State Key Laboratory of Powder Metallurgy, Central South University, Changsha 410083, China
| | - Yuanming Huo
- School of Mechanical and Automotive Engineering, Shanghai University of Engineering Science, Shanghai 201620, China
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16
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Chandhanayingyong C, Thanapipatsiri P, Pairojboriboon S, Luenam S, Hongsaprabhas C, Charoenlap C, Wattanapaiboon K, Asavamongkolkul A, Tharmviboonsri T, Phimolsarnti R. What Are the MSTS Scores and Complications Associated With the Use of Three-dimensional Printed, Custom-made Prostheses in Patients Who Had Resection of Tumors of the Hand and Foot? Clin Orthop Relat Res 2023; 481:2223-2235. [PMID: 37339168 PMCID: PMC10566964 DOI: 10.1097/corr.0000000000002730] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Received: 10/15/2022] [Revised: 03/10/2023] [Accepted: 05/17/2023] [Indexed: 06/22/2023]
Abstract
BACKGROUND There are a few good options for restoring bone defects in the hand and foot. 3D-printed implants have been used in the pelvis and elsewhere, but to our knowledge, they have not been evaluated in the hand and foot. The functional outcome, complications, and longevity of 3D-printed prostheses in small bones are not well known. QUESTIONS/PURPOSES (1) What are the functional outcomes of patients with hand or foot tumors who were treated with tumor resection and reconstruction with a 3D-printed custom prosthesis? (2) What complications are associated with using these prostheses? (3) What is the 5-year Kaplan-Meier cumulative incidence of implant breakage and reoperation? METHODS Between January 2017 and October 2020, we treated 276 patients who had tumors of the hands or feet. Of those, we considered as potentially eligible patients who might have extensive loss in their joint that could not be fixed with a bone graft, cement, or any prostheses available on the market. Based on this, 93 patients were eligible; a further 77 were excluded because they received nonoperative treatment such as chemoradiation, resection without reconstruction, reconstruction using other materials, or ray amputation; another three were lost before the minimum study follow-up of 2 years and two had incomplete datasets, leaving 11 for analysis in this retrospective study. There were seven women and four men. The median age was 29 years (range 11 to 71 years). There were five hand tumors and six tumors of the feet. Tumor types were giant cell tumor of bone (five), chondroblastoma (two), osteosarcoma (two), neuroendocrine tumor (one), and squamous cell carcinoma (one). Margin status after resection was ≥ 1 mm. All patients were followed for a minimum of 24 months. The median follow-up time was 47 months (range 25 to 67 months). Clinical data; function according to the Musculoskeletal Tumor Society, DASH, and American Orthopedic Foot and Ankle Society scores; complications; and survivorship of implants were recorded during follow-up in the clinic, or patients with complete charts and recorded data were interviewed on the telephone by our research associates, orthopaedic oncology fellows, or the surgeons who performed the surgery. The cumulative incidence of implant breakage and reoperation was assessed using a Kaplan-Meier analysis. RESULTS The median Musculoskeletal Tumor Society score was 28 of 30 (range 21 to 30). Seven of 11 patients experienced postoperative complications, primarily including hyperextension deformity and joint stiffness (three patients), joint subluxation (two), aseptic loosening (one), broken stem (one), and broken plate (one), but no infection or local recurrence occurred. Subluxations of the metacarpophalangeal and proximal interphalangeal joints in two patients' hands were caused by the design of the prosthesis without a joint or stem. These prostheses were revised to a second-generation prosthesis with joint and stem, leading to improved dexterity. The cumulative incidence of implant breakage and reoperation in the Kaplan-Meier analysis was 35% (95% CI 6% to 69%) and 29% (95% CI 3% to 66%) at 5 years, respectively. CONCLUSION These preliminary findings suggest that 3D implants may be an option for reconstruction after resections that leave large bone and joint defects in the hand and foot. Although the functional results generally appeared to be good to excellent, complications and reoperations were frequent; thus, we believe this approach could be considered when patients have few or no alternatives other than amputation. Future studies will need to compare this approach to bone grafting or bone cementation. LEVEL OF EVIDENCE Level IV, therapeutic study.
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Affiliation(s)
| | - Pannin Thanapipatsiri
- Department of Orthopaedic Surgery, Faculty of Medicine, Siriraj Hospital, Mahidol University, Bangkok, Thailand
| | - Sutipat Pairojboriboon
- Department of Orthopaedics, Phramongkutklao Hospital and College of Medicine, Bangkok, Thailand
| | - Suriya Luenam
- Department of Orthopaedics, Phramongkutklao Hospital and College of Medicine, Bangkok, Thailand
| | - Chindanai Hongsaprabhas
- Department of Orthopaedics, Faculty of Medicine, Chulalongkorn University, Bangkok, Thailand
| | - Chris Charoenlap
- Department of Orthopaedics, Faculty of Medicine, Chulalongkorn University, Bangkok, Thailand
| | - Komkrich Wattanapaiboon
- Department of Orthopedic Surgery, Queen Savang Vadhana Memorial Hospital, Chonburi, Thailand
| | - Apichat Asavamongkolkul
- Department of Orthopaedic Surgery, Faculty of Medicine, Siriraj Hospital, Mahidol University, Bangkok, Thailand
| | - Theerawoot Tharmviboonsri
- Department of Orthopaedic Surgery, Faculty of Medicine, Siriraj Hospital, Mahidol University, Bangkok, Thailand
| | - Rapin Phimolsarnti
- Department of Orthopaedic Surgery, Faculty of Medicine, Siriraj Hospital, Mahidol University, Bangkok, Thailand
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17
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Zhou J, See CW, Sreenivasamurthy S, Zhu D. Customized Additive Manufacturing in Bone Scaffolds-The Gateway to Precise Bone Defect Treatment. RESEARCH (WASHINGTON, D.C.) 2023; 6:0239. [PMID: 37818034 PMCID: PMC10561823 DOI: 10.34133/research.0239] [Citation(s) in RCA: 5] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 08/07/2023] [Accepted: 09/07/2023] [Indexed: 10/12/2023]
Abstract
In the advancing landscape of technology and novel material development, additive manufacturing (AM) is steadily making strides within the biomedical sector. Moving away from traditional, one-size-fits-all implant solutions, the advent of AM technology allows for patient-specific scaffolds that could improve integration and enhance wound healing. These scaffolds, meticulously designed with a myriad of geometries, mechanical properties, and biological responses, are made possible through the vast selection of materials and fabrication methods at our disposal. Recognizing the importance of precision in the treatment of bone defects, which display variability from macroscopic to microscopic scales in each case, a tailored treatment strategy is required. A patient-specific AM bone scaffold perfectly addresses this necessity. This review elucidates the pivotal role that customized AM bone scaffolds play in bone defect treatment, while offering comprehensive guidelines for their customization. This includes aspects such as bone defect imaging, material selection, topography design, and fabrication methodology. Additionally, we propose a cooperative model involving the patient, clinician, and engineer, thereby underscoring the interdisciplinary approach necessary for the effective design and clinical application of these customized AM bone scaffolds. This collaboration promises to usher in a new era of bioactive medical materials, responsive to individualized needs and capable of pushing boundaries in personalized medicine beyond those set by traditional medical materials.
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Affiliation(s)
- Juncen Zhou
- Department of Biomedical Engineering,
Stony Brook University, Stony Brook, NY, USA
| | - Carmine Wang See
- Department of Biomedical Engineering,
Stony Brook University, Stony Brook, NY, USA
| | - Sai Sreenivasamurthy
- Department of Biomedical Engineering,
Stony Brook University, Stony Brook, NY, USA
| | - Donghui Zhu
- Department of Biomedical Engineering,
Stony Brook University, Stony Brook, NY, USA
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18
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Liang W, Zhou C, Zhang H, Bai J, Jiang B, Jiang C, Ming W, Zhang H, Long H, Huang X, Zhao J. Recent advances in 3D printing of biodegradable metals for orthopaedic applications. J Biol Eng 2023; 17:56. [PMID: 37644461 PMCID: PMC10466721 DOI: 10.1186/s13036-023-00371-7] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/01/2023] [Accepted: 07/31/2023] [Indexed: 08/31/2023] Open
Abstract
The use of biodegradable polymers for treating bone-related diseases has become a focal point in the field of biomedicine. Recent advancements in material technology have expanded the range of materials suitable for orthopaedic implants. Three-dimensional (3D) printing technology has become prevalent in healthcare, and while organ printing is still in its early stages and faces ethical and technical hurdles, 3D printing is capable of creating 3D structures that are supportive and controllable. The technique has shown promise in fields such as tissue engineering and regenerative medicine, and new innovations in cell and bio-printing and printing materials have expanded its possibilities. In clinical settings, 3D printing of biodegradable metals is mainly used in orthopedics and stomatology. 3D-printed patient-specific osteotomy instruments, orthopedic implants, and dental implants have been approved by the US FDA for clinical use. Metals are often used to provide support for hard tissue and prevent complications. Currently, 70-80% of clinically used implants are made from niobium, tantalum, nitinol, titanium alloys, cobalt-chromium alloys, and stainless steels. However, there has been increasing interest in biodegradable metals such as magnesium, calcium, zinc, and iron, with numerous recent findings. The advantages of 3D printing, such as low manufacturing costs, complex geometry capabilities, and short fabrication periods, have led to widespread adoption in academia and industry. 3D printing of metals with controllable structures represents a cutting-edge technology for developing metallic implants for biomedical applications. This review explores existing biomaterials used in 3D printing-based orthopedics as well as biodegradable metals and their applications in developing metallic medical implants and devices. The challenges and future directions of this technology are also discussed.
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Grants
- (LGF22H060023 to WQL) Public Technology Applied Research Projects of Zhejiang Province
- (2022KY433 to WQL, 2023KY1303 to HGL) Medical and Health Research Project of Zhejiang Province
- (2022KY433 to WQL, 2023KY1303 to HGL) Medical and Health Research Project of Zhejiang Province
- (2021FSYYZY45 to WQL) Research Fund Projects of The Affiliated Hospital of Zhejiang Chinese Medicine University
- (2022C31034 to CZ, 2023C31019 to HJZ) Science and Technology Project of Zhoushan
- (2022C31034 to CZ, 2023C31019 to HJZ) Science and Technology Project of Zhoushan
- (2022ZB380 to JYZ, 2023016295 to WYM, 2023007231 to CYJ ) Traditional Chinese Medicine Science and Technology Projects of Zhejiang Province
- (2022ZB380 to JYZ, 2023016295 to WYM, 2023007231 to CYJ ) Traditional Chinese Medicine Science and Technology Projects of Zhejiang Province
- (2022ZB380 to JYZ, 2023016295 to WYM, 2023007231 to CYJ ) Traditional Chinese Medicine Science and Technology Projects of Zhejiang Province
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Affiliation(s)
- Wenqing Liang
- Department of Orthopaedics, Zhoushan Hospital of Traditional Chinese Medicine, Zhejiang Chinese Medical University, 355 Xinqiao Road, Dinghai District, Zhoushan, 316000 Zhejiang Province China
| | - Chao Zhou
- Department of Orthopedics, Zhoushan Guanghua Hospital, Zhoushan, 316000 China
| | - Hongwei Zhang
- Department of Orthopaedics, Zhoushan Hospital of Traditional Chinese Medicine, Zhejiang Chinese Medical University, 355 Xinqiao Road, Dinghai District, Zhoushan, 316000 Zhejiang Province China
| | - Juqin Bai
- Department of Orthopaedics, Zhoushan Hospital of Traditional Chinese Medicine, Zhejiang Chinese Medical University, 355 Xinqiao Road, Dinghai District, Zhoushan, 316000 Zhejiang Province China
| | - Bo Jiang
- Rehabilitation Department, Zhoushan Hospital of Traditional Chinese Medicine, Zhejiang Chinese Medical University, Zhoushan, 316000 China
| | - Chanyi Jiang
- Department of Orthopedics, Zhoushan Hospital of Traditional Chinese Medicine, Zhejiang Chinese Medical University, Zhoushan, 316000 Zhejiang Province P.R. China
| | - Wenyi Ming
- Department of Orthopaedics, Zhoushan Hospital of Traditional Chinese Medicine, Zhejiang Chinese Medical University, 355 Xinqiao Road, Dinghai District, Zhoushan, 316000 Zhejiang Province China
| | - Hengjian Zhang
- Department of Orthopaedics, Zhoushan Hospital of Traditional Chinese Medicine, Zhejiang Chinese Medical University, 355 Xinqiao Road, Dinghai District, Zhoushan, 316000 Zhejiang Province China
| | - Hengguo Long
- Department of Orthopaedics, Zhoushan Hospital of Traditional Chinese Medicine, Zhejiang Chinese Medical University, 355 Xinqiao Road, Dinghai District, Zhoushan, 316000 Zhejiang Province China
| | - Xiaogang Huang
- Department of Orthopaedics, Zhoushan Hospital of Traditional Chinese Medicine, Zhejiang Chinese Medical University, 355 Xinqiao Road, Dinghai District, Zhoushan, 316000 Zhejiang Province China
| | - Jiayi Zhao
- Department of Orthopaedics, Zhoushan Hospital of Traditional Chinese Medicine, Zhejiang Chinese Medical University, 355 Xinqiao Road, Dinghai District, Zhoushan, 316000 Zhejiang Province China
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19
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Alinejadian N, Wang P, Kollo L, Prashanth KG. Selective Laser Melting of Commercially Pure Molybdenum by Laser Rescanning. 3D PRINTING AND ADDITIVE MANUFACTURING 2023; 10:785-791. [PMID: 37614803 PMCID: PMC10442686 DOI: 10.1089/3dp.2021.0265] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 08/25/2023]
Abstract
Commercially pure (cp) molybdenum (Mo) is one of the high-temperature materials of immense potential. It has a body-centered cubic (bcc) structure so it is hard to fabricate using nonequilibrium processes such as the selective laser melting (SLM) without the formation of cracks due to its inherent brittleness. This study deals with the fabrication of dense and near crack-free cp-Mo samples produced by the SLM. The laser scan strategy is adjusted from a single scan to a double scan to reduce the solidification cracks. Samples produced with a laser double scan strategy show a density of ∼99% with a hardness of ∼222 HV.
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Affiliation(s)
- Navid Alinejadian
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology (TalTech), Tallinn, Estonia
| | - Pei Wang
- Additive Manufacturing Institute, Shenzhen University, Shenzhen, P.R. China
| | - Lauri Kollo
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology (TalTech), Tallinn, Estonia
| | - Konda Gokuldoss Prashanth
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology (TalTech), Tallinn, Estonia
- Erich Schmid Institute of Materials Science, Austrian Academy of Sciences, Leoben, Austria
- CBCMT, School of Mechanical Engineering, Vellore Institute of Technology, Vellore, India
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20
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Andreacola FR, Capasso I, Langella A, Brando G. 3D-printed metals: Process parameters effects on mechanical properties of 17-4 P H stainless steel. Heliyon 2023; 9:e17698. [PMID: 37483809 PMCID: PMC10362090 DOI: 10.1016/j.heliyon.2023.e17698] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/17/2023] [Revised: 05/26/2023] [Accepted: 06/26/2023] [Indexed: 07/25/2023] Open
Abstract
Additive Manufacturing (AM) has spread significantly in recent years, with relevant applications in many fields of research and engineering. Thanks to its distinctive production methods, AM enables the creation of parts with complex shapes that cannot be fabricated easily by employing traditional subtractive processes. 3D printing, which involves overlapping material layer by layer until the designed part is completed, shows several advantages in terms of limiting material waste, reducing production phases and postprocessing/heat treatments needs, leading to an additional benefit in terms of environmental sustainability. However, there are still limited available data on the influence of the 3D printing process on the mechanical properties of the materials that are commonly used and additional investigations are strongly demanded. So, the purpose of the present paper is to provide a useful contribution in the field of metal additive manufacturing, reporting the results of an experimental campaign carried out on 17-4 P H stainless steel, produced using selective laser melting technology. The effects of different printing orientations and scanning times on the tensile behaviour, impact strength and microhardness features of the 3D-printed products are investigated. Furthermore, the influence of an annealing heat treatment on the material mechanical performance is evaluated.
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Affiliation(s)
- Francesca Romana Andreacola
- Department of Engineering and Geology, University “G. D’Annunzio” of Chieti-Pescara, Viale Pindaro 42, 65127, Pescara, Italy
| | - Ilaria Capasso
- Department of Engineering and Geology, University “G. D’Annunzio” of Chieti-Pescara, Viale Pindaro 42, 65127, Pescara, Italy
| | - Antonio Langella
- Department of Chemical, Materials and Production Engineering, University of Naples Federico II, Piazzale Tecchio 80, 80125, Naples, Italy
| | - Giuseppe Brando
- Department of Engineering and Geology, University “G. D’Annunzio” of Chieti-Pescara, Viale Pindaro 42, 65127, Pescara, Italy
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21
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Liović D, Franulović M, Kamenar E, Kozak D. Nano-Mechanical Behavior of Ti6Al4V Alloy Manufactured Using Laser Powder Bed Fusion. MATERIALS (BASEL, SWITZERLAND) 2023; 16:4341. [PMID: 37374525 DOI: 10.3390/ma16124341] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/04/2023] [Revised: 06/02/2023] [Accepted: 06/08/2023] [Indexed: 06/29/2023]
Abstract
The microstructure of Ti6Al4V alloy, manufactured using laser powder bed fusion (L-PBF), is affected by process parameters and heat treatment. However, their influence on the nano-mechanical behavior of this widely applicable alloy is still unknown and scarcely reported. This study aims to investigate the influence of the frequently used annealing heat treatment on mechanical properties, strain-rate sensitivity, and creep behavior of L-PBF Ti6Al4V alloy. Furthermore, the influence of different utilized L-PBF laser power-scanning speed combinations on mechanical properties of annealed specimens has been studied as well. It has been found that the effect of high laser power remains present in the microstructure even after annealing, resulting in increase in nano-hardness. Moreover, the linear relation between the Young's modulus and the nano-hardness after annealing has been established. Thorough creep analysis revealed dislocation motion as a dominant deformation mechanism, both for as-built and annealed conditions of the specimens. Although annealing heat treatment is beneficial and widely recommended, it reduces the creep resistance of Ti6Al4V alloy manufactured using L-PBF. The results presented within this research article contribute to the L-PBF process parameter selection, as well as to understanding the creep behavior of these novel and widely applicable materials.
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Affiliation(s)
- David Liović
- Faculty of Engineering, University of Rijeka, Vukovarska 58, 51000 Rijeka, Croatia
| | - Marina Franulović
- Faculty of Engineering, University of Rijeka, Vukovarska 58, 51000 Rijeka, Croatia
| | - Ervin Kamenar
- Faculty of Engineering, University of Rijeka, Vukovarska 58, 51000 Rijeka, Croatia
| | - Dražan Kozak
- Mechanical Engineering Faculty in Slavonski Brod, University of Slavonski Brod, Trg I. B. Mažuranić 2, 35000 Slavonski Brod, Croatia
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22
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Yao L, Ramesh A, Xiao Z, Chen Y, Zhuang Q. Multimetal Research in Powder Bed Fusion: A Review. MATERIALS (BASEL, SWITZERLAND) 2023; 16:4287. [PMID: 37374471 DOI: 10.3390/ma16124287] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/03/2023] [Revised: 06/02/2023] [Accepted: 06/05/2023] [Indexed: 06/29/2023]
Abstract
This article discusses the different forms of powder bed fusion (PBF) techniques, namely laser powder bed fusion (LPBF), electron beam powder bed fusion (EB-PBF) and large-area pulsed laser powder bed fusion (L-APBF). The challenges faced in multimetal additive manufacturing, including material compatibility, porosity, cracks, loss of alloying elements and oxide inclusions, have been extensively discussed. Solutions proposed to overcome these challenges include the optimization of printing parameters, the use of support structures, and post-processing techniques. Future research on metal composites, functionally graded materials, multi-alloy structures and materials with tailored properties are needed to address these challenges and improve the quality and reliability of the final product. The advancement of multimetal additive manufacturing can offer significant benefits for various industries.
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Affiliation(s)
- Liming Yao
- State Key Laboratory of Robotics and Systems (HIT), Harbin 150000, China
- School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore
| | - Aditya Ramesh
- School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore
| | - Zhongmin Xiao
- School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore
| | - Yang Chen
- School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore
| | - Quihui Zhuang
- School of Mechanical Engineering, Chongqing University of Technology, Chongqing 400054, China
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23
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Shanmuganathan PK, Purushothaman DB, Ponnusamy M. Effect of High Laser Energy Density on Selective Laser Melted 316L Stainless Steel: Analysis on Metallurgical and Mechanical Properties and Comparison with Wrought 316L Stainless Steel. 3D PRINTING AND ADDITIVE MANUFACTURING 2023; 10:383-392. [PMID: 37346193 PMCID: PMC10280227 DOI: 10.1089/3dp.2021.0061] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/23/2023]
Abstract
The austenitic 316L stainless steel (SS) is used extensively for marine applications as well as in construction, processing, and petrochemical industries due to its outstanding corrosion resistance properties. This study investigates the density, microhardness, and microstructural development of 316L SS samples fabricated by selective laser melting (SLM) under high laser energy densities. The selective laser melted (SLMed) specimens were fabricated under high laser energy densities (500, 400, and 333.33 J/mm3) and their metallurgical and mechanical properties were compared with the wrought specimen. SLMed 316L SS showed excellent printability, thereby enabling the fabrication of parts near full density. The porosity content present in the SLMed specimens was determined by both the image analysis method and Archimedes method. SLMed 316L specimens fabricated by the SLM process allowed observation of a microhardness of 253 HV1.0 and achieved relative density up to 98.022%. Microstructural analysis using optical microscopy and phase composition analysis by X-ray diffraction (XRD) has been performed. Residual stresses were observed using the XRD method, and compressive stress (-68.9 MPa) was noticed in the as-printed specimen along the surface of the build direction. The microstructure of the as-built SLMed specimens consisted of a single-phase face-centered cubic solid solution with fine cellular and columnar grains along the build direction. The SLMed specimens seemed to yield better results than the wrought counterpart. IRB approval and Clinical Trial Registration Number are not applicable for this current work.
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Affiliation(s)
| | | | - Marimuthu Ponnusamy
- School of Mechanical Engineering, SASTRA Deemed University, Thanjavur, India
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24
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Aiba H, Spazzoli B, Tsukamoto S, Mavrogenis AF, Hermann T, Kimura H, Murakami H, Donati DM, Errani C. Current Concepts in the Resection of Bone Tumors Using a Patient-Specific Three-Dimensional Printed Cutting Guide. Curr Oncol 2023; 30:3859-3870. [PMID: 37185405 PMCID: PMC10136997 DOI: 10.3390/curroncol30040292] [Citation(s) in RCA: 5] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/09/2023] [Revised: 03/25/2023] [Accepted: 03/29/2023] [Indexed: 04/01/2023] Open
Abstract
Orthopedic oncology has begun to use three-dimensional-printing technology, which is expected to improve the accuracy of osteotomies, ensure a safe margin, and facilitate precise surgery. However, several difficulties should be considered. Cadaver and clinical studies have reported more accurate osteotomies for bone-tumor resection using patient-specific cutting guides, especially in challenging areas such as the sacrum and pelvis, compared to manual osteotomies. Patient-specific cutting guides can help surgeons achieve resection with negative margins and reduce blood loss and operating time. Furthermore, this patient-specific cutting guide could be combined with more precise reconstruction using patient-specific implants or massive bone allografts. This review provides an overview of the basic technologies used in the production of patient-specific cutting guides and discusses their current status, advantages, and limitations. Moreover, we summarize cadaveric and clinical studies on the use of these guides in orthopedic oncology.
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Affiliation(s)
- Hisaki Aiba
- Department of Orthopedic Oncology, IRCCS Istituto Ortopedico Rizzoli, Via Pupilli 1, 40136 Bologna, Italy
- Department of Orthopedic Surgery, Nagoya City University, Nagoya 467-8601, Aichi, Japan
| | - Benedetta Spazzoli
- Department of Orthopedic Oncology, IRCCS Istituto Ortopedico Rizzoli, Via Pupilli 1, 40136 Bologna, Italy
| | - Shinji Tsukamoto
- Department of Orthopedic Surgery, Nara Medical University, Kashihara 634-8521, Nara, Japan
| | - Andreas F Mavrogenis
- First Department of Orthopedics, School of Medicine, National and Kapodistrian University of Athens, 11527 Athens, Greece
| | - Tomas Hermann
- Department of Orthopedic Oncology, IRCCS Istituto Ortopedico Rizzoli, Via Pupilli 1, 40136 Bologna, Italy
- Department of Tumors, HTC Hospital, Traumagologico Concepcion, 1580 San Martin, Concepcion 4030000, Chile
| | - Hiroaki Kimura
- Department of Orthopedic Surgery, Nagoya City University, Nagoya 467-8601, Aichi, Japan
| | - Hideki Murakami
- Department of Orthopedic Surgery, Nagoya City University, Nagoya 467-8601, Aichi, Japan
| | - Davide Maria Donati
- Department of Orthopedic Oncology, IRCCS Istituto Ortopedico Rizzoli, Via Pupilli 1, 40136 Bologna, Italy
| | - Costantino Errani
- Department of Orthopedic Oncology, IRCCS Istituto Ortopedico Rizzoli, Via Pupilli 1, 40136 Bologna, Italy
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25
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Mohanty S, Gokuldoss Prashanth K. Metallic Coatings through Additive Manufacturing: A Review. MATERIALS (BASEL, SWITZERLAND) 2023; 16:2325. [PMID: 36984204 PMCID: PMC10056185 DOI: 10.3390/ma16062325] [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: 01/18/2023] [Revised: 02/24/2023] [Accepted: 02/27/2023] [Indexed: 06/18/2023]
Abstract
Metallic additive manufacturing is expeditiously gaining attention in advanced industries for manufacturing intricate structures for customized applications. However, the inadequate surface quality has inspired the inception of metallic coatings through additive manufacturing methods. This work presents a brief review of the different genres of metallic coatings adapted by industries through additive manufacturing technologies. The methodologies are classified according to the type of allied energies used in the process, such as direct energy deposition, binder jetting, powder bed fusion, hot spray coatings, sheet lamination, etc. Each method is described in detail and supported by relevant literature. The paper also includes the needs, applications, and challenges involved in each process.
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Affiliation(s)
- Shalini Mohanty
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology, 12818 Tallinn, Estonia
| | - Konda Gokuldoss Prashanth
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology, 12818 Tallinn, Estonia
- CBCMT, School of Mechanical Engineering, Vellore Institute of Technology, Vellore 630014, Tamil Nadu, India
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26
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Bhagat K, Rudraraju S. A Numerical Investigation of Dimensionless Numbers Characterizing Meltpool Morphology of the Laser Powder Bed Fusion Process. MATERIALS (BASEL, SWITZERLAND) 2022; 16:94. [PMID: 36614432 PMCID: PMC9821554 DOI: 10.3390/ma16010094] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/11/2022] [Revised: 12/06/2022] [Accepted: 12/15/2022] [Indexed: 06/17/2023]
Abstract
Microstructure evolution in metal additive manufacturing (AM) is a complex multi-physics and multi-scale problem. Understanding the impact of AM process conditions on the microstructure evolution and the resulting mechanical properties of the printed component remains an active area of research. At the meltpool scale, the thermo-fluidic governing equations have been extensively modeled in the literature to understand the meltpool conditions and the thermal gradients in its vicinity. In many phenomena governed by partial differential equations, dimensional analysis and identification of important dimensionless numbers can provide significant insights into the process dynamics. In this context, we present a novel strategy using dimensional analysis and the linear least-squares regression method to numerically investigate the thermo-fluidic governing equations of the Laser Powder Bed Fusion AM process. First, the governing equations are solved using the Finite Element Method, and the model predictions are validated by comparing with experimentally estimated cooling rates, and with numerical results from the literature. Then, through dimensional analysis, an important dimensionless quantity interpreted as a measure of heat absorbed by the powdered material and the meltpool, is identified. This dimensionless measure of absorbed heat, along with classical dimensionless quantities such as Péclet, Marangoni, and Stefan numbers, are employed to investigate advective transport in the meltpool for different alloys. Further, the framework is used to study variations in the thermal gradients and the solidification cooling rate. Important correlations linking meltpool morphology and microstructure-evolution-related variables with classical dimensionless numbers are the key contribution of this work.
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Affiliation(s)
| | - Shiva Rudraraju
- Department of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA
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27
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Avanzini A. Fatigue Behavior of Additively Manufactured Stainless Steel 316L. MATERIALS (BASEL, SWITZERLAND) 2022; 16:65. [PMID: 36614414 PMCID: PMC9820919 DOI: 10.3390/ma16010065] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/23/2022] [Revised: 12/16/2022] [Accepted: 12/17/2022] [Indexed: 06/17/2023]
Abstract
316L stainless steel is the material of choice for several critical applications in which a combination of mechanical strength and resistance to corrosion is required, as in the biomedical field. Additive Manufacturing (AM) technologies can pave the way to new design solutions, but microstructure, defect types, and surface characteristics are substantially different in comparison to traditional processing routes, making the assessment of the long-term durability of AM materials and components a crucial aspect. In this paper a thorough review is presented of the relatively large body of recent literature devoted to investigations on fatigue of AM 316L, focusing on the comparison between different AM technologies and conventional processes and on the influence of processing and post-processing aspects in terms of fatigue strength and lifetime. Overall fatigue data are quite scattered, but the dependency of fatigue performances on surface finish, building orientation, and type of heat treatment can be clearly appreciated, as well as the influence of different printing processes. A critical discussion on the different testing approaches presented in the literature is also provided, highlighting the need for shared experimental test protocols and data presentation in order to better understand the complex correlations between fatigue behavior and processing parameters.
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Affiliation(s)
- Andrea Avanzini
- Department of Industrial and Mechanical Engineering, University of Brescia, 25128 Brescia, Italy
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28
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TK diagrams to determine the impact of pH variation on 3D printed CoCr alloy implant corrosion. J Electroanal Chem (Lausanne) 2022. [DOI: 10.1016/j.jelechem.2022.117087] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/23/2022]
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29
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Emerging 4D printing strategies for on-demand local actuation & micro printing of soft materials. Eur Polym J 2022. [DOI: 10.1016/j.eurpolymj.2022.111778] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/23/2022]
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30
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Akshaya S, Rowlo PK, Dukle A, Nathanael AJ. Antibacterial Coatings for Titanium Implants: Recent Trends and Future Perspectives. Antibiotics (Basel) 2022; 11:antibiotics11121719. [PMID: 36551376 PMCID: PMC9774638 DOI: 10.3390/antibiotics11121719] [Citation(s) in RCA: 22] [Impact Index Per Article: 11.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/04/2022] [Revised: 11/24/2022] [Accepted: 11/25/2022] [Indexed: 12/02/2022] Open
Abstract
Titanium and its alloys are widely used as implant materials for biomedical devices owing to their high mechanical strength, biocompatibility, and corrosion resistance. However, there is a significant rise in implant-associated infections (IAIs) leading to revision surgeries, which are more complicated than the original replacement surgery. To reduce the risk of infections, numerous antibacterial agents, e.g., bioactive compounds, metal ions, nanoparticles, antimicrobial peptides, polymers, etc., have been incorporated on the surface of the titanium implant. Various coating methods and surface modification techniques, e.g., micro-arc oxidation (MAO), layer-by-layer (LbL) assembly, plasma electrolytic oxidation (PEO), anodization, magnetron sputtering, and spin coating, are exploited in the race to create a biocompatible, antibacterial titanium implant surface that can simultaneously promote tissue integration around the implant. The nature and surface morphology of implant coatings play an important role in bacterial inhibition and drug delivery. Surface modification of titanium implants with nanostructured materials, such as titanium nanotubes, enhances bone regeneration. Antimicrobial peptides loaded with antibiotics help to achieve sustained drug release and reduce the risk of antibiotic resistance. Additive manufacturing of patient-specific porous titanium implants will have a clear future direction in the development of antimicrobial titanium implants. In this review, a brief overview of the different types of coatings that are used to prevent implant-associated infections and the applications of 3D printing in the development of antibacterial titanium implants is presented.
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Affiliation(s)
- S. Akshaya
- Centre for Biomaterials, Cellular and Molecular Theranostics (CBCMT), Vellore Institute of Technology, Vellore 632014, India
- School of Advanced Sciences, Vellore Institute of Technology, Vellore 632014, India
| | - Praveen Kumar Rowlo
- Centre for Biomaterials, Cellular and Molecular Theranostics (CBCMT), Vellore Institute of Technology, Vellore 632014, India
- School of Bio Sciences & Technology, Vellore Institute of Technology, Vellore 632014, India
| | - Amey Dukle
- Centre for Biomaterials, Cellular and Molecular Theranostics (CBCMT), Vellore Institute of Technology, Vellore 632014, India
- School of Bio Sciences & Technology, Vellore Institute of Technology, Vellore 632014, India
| | - A. Joseph Nathanael
- Centre for Biomaterials, Cellular and Molecular Theranostics (CBCMT), Vellore Institute of Technology, Vellore 632014, India
- Correspondence:
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31
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Sharma SK, Grewal HS, Saxena KK, Mohammed KA, Prakash C, Davim JP, Buddhi D, Raju R, Mohan DG, Tomków J. Advancements in the Additive Manufacturing of Magnesium and Aluminum Alloys through Laser-Based Approach. MATERIALS (BASEL, SWITZERLAND) 2022; 15:8122. [PMID: 36431608 PMCID: PMC9698782 DOI: 10.3390/ma15228122] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 09/30/2022] [Revised: 11/01/2022] [Accepted: 11/09/2022] [Indexed: 06/16/2023]
Abstract
Complex structures can now be manufactured easily utilizing AM technologies to meet the pre-requisite objectives such as reduced part numbers, greater functionality, and lightweight, among others. Polymers, metals, and ceramics are the few materials that can be used in AM technology, but metallic materials (Magnesium and Aluminum) are attracting more attention from the research and industrial point of view. Understanding the role processing parameters of laser-based additive manufacturing is critical to maximize the usage of material in forming the product geometry. LPBF (Laser powder-based fusion) method is regarded as a potent and effective additive manufacturing technique for creating intricate 3D forms/parts with high levels of precision and reproducibility together with acceptable metallurgical characteristics. While dealing with LBPF, some degree of porosity is acceptable because it is unavoidable; hot ripping and cracking must be avoided, though. The necessary manufacturing of pre-alloyed powder and ductility remains to be the primary concern while dealing with a laser-based additive manufacturing approach. The presence of the Al-Si eutectic phase in AlSi10Mg and AlSi12 alloy attributing to excellent castability and low shrinkage, attaining the most attention in the laser-based approach. Related studies with these alloys along with precipitation hardening and heat treatment processing were discussed. The Pure Mg, Mg-Al alloy, Mg-RE alloy, and Mg-Zn alloy along with the mechanical characteristics, electrochemical durability, and biocompatibility of Mg-based material have been elaborated in the work-study. The review article also summarizes the processing parameters of the additive manufacturing powder-based approach relating to different Mg-based alloys. For future aspects, the optimization of processing parameters, composition of the alloy, and quality of powder material used will significantly improve the ductility of additively manufactured Mg alloy by the LPBF approach. Other than that, the recycling of Mg-alloy powder hasn't been investigated yet. Meanwhile, the post-processing approach, including a homogeneous coating on the porous scaffolds, will mark the suitability in terms of future advancements in Mg and Al-based alloys.
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Affiliation(s)
- Sachin Kumar Sharma
- Surface Science and Tribology Lab, Department of Mechanical Engineering, Shiv Nadar Institute of Eminence, Gautam Buddha Nagar 201314, Uttar Pradesh, India
| | - Harpreet Singh Grewal
- Surface Science and Tribology Lab, Department of Mechanical Engineering, Shiv Nadar Institute of Eminence, Gautam Buddha Nagar 201314, Uttar Pradesh, India
| | - Kuldeep Kumar Saxena
- Department of Mechanical Engineering, GLA University, Mathura 281406, Uttar Pradesh, India
| | - Kahtan A. Mohammed
- Department of Medical Physics, Hilla University College, Babylon 51002, Iraq
| | - Chander Prakash
- Division of Research and Development, Lovely Professional University, Phagwara 144001, Punjab, India
| | - J. Paulo Davim
- Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal
| | - Dharam Buddhi
- Division of Research & Innovation, Uttaranchal University, Dehradun 248007, Uttarakhand, India
| | - Ramesh Raju
- Department of Mechanical Engineering, Sree Vidyanikethan Engineering College (Autonomous), Tirupathi 517102, Andhra Pradesh, India
| | - Dhanesh G. Mohan
- Department of Material Processing Engineering, Zhengzhou Research Institute of Harbin Institute of Technology, Zhengzhou 450002, China
| | - Jacek Tomków
- Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, 80-229 Gdańsk, Poland
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32
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Hüner B, Kıstı M, Uysal S, Uzgören İN, Özdoğan E, Süzen YO, Demir N, Kaya MF. An Overview of Various Additive Manufacturing Technologies and Materials for Electrochemical Energy Conversion Applications. ACS OMEGA 2022; 7:40638-40658. [PMID: 36406513 PMCID: PMC9670698 DOI: 10.1021/acsomega.2c05096] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 08/09/2022] [Accepted: 10/20/2022] [Indexed: 06/16/2023]
Abstract
Additive manufacturing (AM) technologies have many advantages, such as design flexibility, minimal waste, manufacturing of very complex structures, cheaper production, and rapid prototyping. This technology is widely used in many fields, including health, energy, art, design, aircraft, and automotive sectors. In the manufacturing process of 3D printed products, it is possible to produce different objects with distinctive filament and powder materials using various production technologies. AM covers several 3D printing techniques such as fused deposition modeling (FDM), inkjet printing, selective laser melting (SLM), and stereolithography (SLA). The present review provides an extensive overview of the recent progress in 3D printing methods for electrochemical fields. A detailed review of polymeric and metallic 3D printing materials and their corresponding printing methods for electrodes is also presented. Finally, this paper comprehensively discusses the main benefits and the drawbacks of electrode production from AM methods for energy conversion systems.
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Affiliation(s)
- Bulut Hüner
- Engineering
Faculty, Energy Systems Engineering Department, Heat Engineering Division, Erciyes University, 38039 Kayseri, Turkey
- Erciyes
University H2FC Hydrogen Energy Research Group, 38039 Kayseri, Turkey
| | - Murat Kıstı
- Engineering
Faculty, Energy Systems Engineering Department, Heat Engineering Division, Erciyes University, 38039 Kayseri, Turkey
- Erciyes
University H2FC Hydrogen Energy Research Group, 38039 Kayseri, Turkey
| | - Süleyman Uysal
- Engineering
Faculty, Energy Systems Engineering Department, Heat Engineering Division, Erciyes University, 38039 Kayseri, Turkey
- Erciyes
University H2FC Hydrogen Energy Research Group, 38039 Kayseri, Turkey
- BATARYASAN
Enerji ve San. Tic. Ltd. Şti, Yıldırım
Beyazıt Mah., Aşık Veysel Bul., ERÜ TGB İdare ve Kuluçka 4, No: 67/3/11, Melikgazi, 38039 Kayseri, Turkey
| | - İlayda Nur Uzgören
- Engineering
Faculty, Energy Systems Engineering Department, Heat Engineering Division, Erciyes University, 38039 Kayseri, Turkey
- Erciyes
University H2FC Hydrogen Energy Research Group, 38039 Kayseri, Turkey
| | - Emre Özdoğan
- Engineering
Faculty, Energy Systems Engineering Department, Heat Engineering Division, Erciyes University, 38039 Kayseri, Turkey
- Erciyes
University H2FC Hydrogen Energy Research Group, 38039 Kayseri, Turkey
- BATARYASAN
Enerji ve San. Tic. Ltd. Şti, Yıldırım
Beyazıt Mah., Aşık Veysel Bul., ERÜ TGB İdare ve Kuluçka 4, No: 67/3/11, Melikgazi, 38039 Kayseri, Turkey
| | - Yakup Ogün Süzen
- Engineering
Faculty, Department of Mechanical Engineering, Erciyes University, 38039 Kayseri, Turkey
- Erciyes
University H2FC Hydrogen Energy Research Group, 38039 Kayseri, Turkey
| | - Nesrin Demir
- Engineering
Faculty, Energy Systems Engineering Department, Heat Engineering Division, Erciyes University, 38039 Kayseri, Turkey
- Erciyes
University H2FC Hydrogen Energy Research Group, 38039 Kayseri, Turkey
| | - Mehmet Fatih Kaya
- Engineering
Faculty, Energy Systems Engineering Department, Heat Engineering Division, Erciyes University, 38039 Kayseri, Turkey
- Erciyes
University H2FC Hydrogen Energy Research Group, 38039 Kayseri, Turkey
- BATARYASAN
Enerji ve San. Tic. Ltd. Şti, Yıldırım
Beyazıt Mah., Aşık Veysel Bul., ERÜ TGB İdare ve Kuluçka 4, No: 67/3/11, Melikgazi, 38039 Kayseri, Turkey
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33
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Dudek M, Wawryniuk Z, Nesteruk M, Rosowski A, Cichomski M, Kozicki M, Święcik R. Changes in the Laser-Processed Ti6Al4V Titanium Alloy Surface Observed by Using Raman Spectroscopy. MATERIALS (BASEL, SWITZERLAND) 2022; 15:7153. [PMID: 36295222 PMCID: PMC9609389 DOI: 10.3390/ma15207153] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 09/22/2022] [Revised: 10/07/2022] [Accepted: 10/11/2022] [Indexed: 06/16/2023]
Abstract
This works reports on the effects of treating the surface of Ti6Al4V titanium alloy samples with a laser with a wavelength of 1064 nm, operating in a pulsed and continuous mode. The obtained surfaces with different roughness, complexity and wettability were examined by Raman spectroscopy in order to recognize the presence of titanium oxides on the functionalized surface. The layer of titanium oxides on the surface with the identified rutile phase obtained by laser treatment in the continuous wave mode is a reason for a hydrophobic surface that appeared 50 days after the treatment process. In the case of the surface obtained by the pulsed laser process, only local points at which the Raman bands attributed to the metastable phases anatase and brookite of TiO2 can be identified. In this treatment process, complete surface hydrophilicity was observed during 29 days after the functionalization process (maximal contact angle observed during this time was 68.4 deg). For some functionalization processes of different parameters, the contact angle remained immeasurable until 119 days after the functionalization process. In summary, Raman spectroscopy identifies surface changes of Ti6Al4V after laser processing.
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Affiliation(s)
- Mariusz Dudek
- Institute of Materials Science and Engineering, Lodz University of Technology, Stefanowskiego 1/15, 90-924 Lodz, Poland
| | - Zuzanna Wawryniuk
- Institute of Materials Science and Engineering, Lodz University of Technology, Stefanowskiego 1/15, 90-924 Lodz, Poland
| | - Malwina Nesteruk
- Institute of Materials Science and Engineering, Lodz University of Technology, Stefanowskiego 1/15, 90-924 Lodz, Poland
| | - Adam Rosowski
- SPI Lasers, 3 Wellington Park, Tollbar Way, Hedge End, Southampton, Hampshire SO30 2QU, UK
- Institute for Manufacturing, University of Cambridge, 17 Charles Babbage Road, Cambridge CB3 0FS, UK
| | - Michał Cichomski
- Department of Materials Technology and Chemistry, Faculty of Chemistry, University of Lodz, Pomorska 163, 90-236 Lodz, Poland
| | - Marek Kozicki
- Department of Mechanical Engineering, Informatics and Chemistry of Polymer Materials, Faculty of Materials Technologies and Textile Design, Lodz University of Technology, Żeromskiego 116, 90-924 Lodz, Poland
| | - Robert Święcik
- Institute of Machine Tools and Production Engineering, Lodz University of Technology, Stefanowskiego 1/15, 90-924 Lodz, Poland
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Mirzaali MJ, Moosabeiki V, Rajaai SM, Zhou J, Zadpoor AA. Additive Manufacturing of Biomaterials-Design Principles and Their Implementation. MATERIALS (BASEL, SWITZERLAND) 2022; 15:5457. [PMID: 35955393 PMCID: PMC9369548 DOI: 10.3390/ma15155457] [Citation(s) in RCA: 18] [Impact Index Per Article: 9.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/30/2022] [Revised: 07/25/2022] [Accepted: 07/28/2022] [Indexed: 05/04/2023]
Abstract
Additive manufacturing (AM, also known as 3D printing) is an advanced manufacturing technique that has enabled progress in the design and fabrication of customised or patient-specific (meta-)biomaterials and biomedical devices (e.g., implants, prosthetics, and orthotics) with complex internal microstructures and tuneable properties. In the past few decades, several design guidelines have been proposed for creating porous lattice structures, particularly for biomedical applications. Meanwhile, the capabilities of AM to fabricate a wide range of biomaterials, including metals and their alloys, polymers, and ceramics, have been exploited, offering unprecedented benefits to medical professionals and patients alike. In this review article, we provide an overview of the design principles that have been developed and used for the AM of biomaterials as well as those dealing with three major categories of biomaterials, i.e., metals (and their alloys), polymers, and ceramics. The design strategies can be categorised as: library-based design, topology optimisation, bio-inspired design, and meta-biomaterials. Recent developments related to the biomedical applications and fabrication methods of AM aimed at enhancing the quality of final 3D-printed biomaterials and improving their physical, mechanical, and biological characteristics are also highlighted. Finally, examples of 3D-printed biomaterials with tuned properties and functionalities are presented.
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Affiliation(s)
- Mohammad J. Mirzaali
- Department of Biomechanical Engineering, Faculty of Mechanical, Maritime, and Materials Engineering, Delft University of Technology (TU Delft), Mekelweg 2, 2628 CD Delft, The Netherlands
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35
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Additive Manufacturing of Metallic Components for Hard Coatings. COATINGS 2022. [DOI: 10.3390/coatings12071007] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/10/2022]
Abstract
Metals additive manufacturing is a new concept of fabrication that consists of depositing material layer-by-layer in a very precise and automatized way [...]
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Zou S, Gong H, Gao J. Additively Manufactured Multilevel Voronoi-Lattice Scaffolds with Bonelike Mechanical Properties. ACS Biomater Sci Eng 2022; 8:3022-3037. [PMID: 35537212 DOI: 10.1021/acsbiomaterials.1c01482] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Abstract
Irregular porous scaffold through Voronoi tessellation based on global modeling demonstrated randomness to a certain degree and susceptibility to producing large processing deviations. A modeling method for new types of scaffolds based on periodic arrays of Voronoi unit cell was proposed in this study. These porous scaffolds presented controllable local cells and satisfactory mechanical properties. The topological structure of the Voronoi unit cell was controlled using three independent cell design factors (Voronoi polyhedron volume V, face-centered scaled factor F1, and body-centered scaled factor F2), and multilevel Voronoi-lattice scaffolds were constructed on the basis of periodic arrays of the Voronoi unit cell. Compressive test and simulation were combined to quantify the mechanical properties of scaffolds. The regression equations were established using the response surface method (RSM) to determine relationships between Voronoi unit cell design factors and structural characteristic parameters and mechanical properties. The same trends were observed in stress-strain curves of the compressive test and simulation. The mechanical properties of scaffolds can be appropriately quantified via simulation. Regression equations based on RSM can properly predict the structural characteristic parameters and mechanical properties of the scaffold. Compared with V, F1 and F2 exerted a stronger influence on the structural characteristic parameters and mechanical properties of the scaffold. The modeling method of the multilevel Voronoi-lattice scaffold based on the Voronoi unit cell was proposed in this study to design the porous scaffold and meet the requirements of human bone morphology, mechanical properties, and actual manufacturing by adjusting factors V, F1, and F2. The proposed method can provide a feasible strategy for designing implants with suitable and similar morphologies and mechanical properties to cancellous bone.
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Affiliation(s)
- Shanshan Zou
- Department of Engineering Mechanics, Jilin University, Changchun 130022, People's Republic of China
| | - He Gong
- Department of Engineering Mechanics, Jilin University, Changchun 130022, People's Republic of China
| | - Jiazi Gao
- Department of Engineering Mechanics, Jilin University, Changchun 130022, People's Republic of China
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Kowalczyk J, Ulbrich D, Sędłak K, Nowak M. Adhesive Joints of Additively Manufactured Adherends: Ultrasonic Evaluation of Adhesion Strength. MATERIALS 2022; 15:ma15093290. [PMID: 35591623 PMCID: PMC9099763 DOI: 10.3390/ma15093290] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/11/2022] [Revised: 04/30/2022] [Accepted: 05/01/2022] [Indexed: 12/10/2022]
Abstract
Adhesive joints are widely used in the construction of machines and motor vehicles. Manufacturers replace them with the welding and spot-welding methods due to the lack of damage to the material structure in the joint area. Moreover, it is aimed at reducing the weight of vehicles and producing elements with complex shapes. Therefore, additive manufacturing technology has been increasingly used in the production stage. This fact has not only changed the view on the possibilities of further development of the production technology itself, but it has also caused an intense interest among a greater number of companies in the advantages of structural optimization. There is a natural relationship between these two areas in the design and production, allowing for almost unlimited possibilities of designing new products. The main goal of the research described in this article was to determine the correlation between the strength of the adhesive joint of elements produced using additive technology and the parameters of the ultrasonic wave propagating in the area of the adhesive bond. The tests were carried out on samples made of AlSiMg0.6 material and a structural adhesive. Strength tests were performed to determine the shear force which damaged the joint. Furthermore, an ultrasonic echo technique enabling the determination of a nondestructive measure of the quality and strength of the joint was developed. The samples of the adhesive joints had a strength of about 18.75–28.95 MPa, which corresponded to an ultrasonic measure range of 4.6–7.8 dB. The determined regression relationship had a coefficient of determination at the level of 0.94. Additional ultrasonic tests of materials made with the additive technology confirmed its different acoustic properties in relation to aluminum produced with the standard casting or extrusion process. Designated dependence combining the mechanical strength and the decibel difference between the first and second impulses from the bottom of the joint may constitute the basis for the development of a nondestructive technique for testing the strength of adhesive joints.
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Affiliation(s)
- Jakub Kowalczyk
- Faculty of Transport and Civil Engineering, Institute of Machines and Motor Vehicles, Poznan University of Technology, 60-965 Poznań, Poland;
- Correspondence: ; Tel.: 61-6652248
| | - Dariusz Ulbrich
- Faculty of Transport and Civil Engineering, Institute of Machines and Motor Vehicles, Poznan University of Technology, 60-965 Poznań, Poland;
| | - Kamil Sędłak
- Faculty of Mechanical Engineering, Division of Virtual Engineering, Poznan University of Technology, 60-965 Poznań, Poland; (K.S.); (M.N.)
| | - Michał Nowak
- Faculty of Mechanical Engineering, Division of Virtual Engineering, Poznan University of Technology, 60-965 Poznań, Poland; (K.S.); (M.N.)
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Detamornrat U, McAlister E, Hutton ARJ, Larrañeta E, Donnelly RF. The Role of 3D Printing Technology in Microengineering of Microneedles. SMALL (WEINHEIM AN DER BERGSTRASSE, GERMANY) 2022; 18:e2106392. [PMID: 35362226 DOI: 10.1002/smll.202106392] [Citation(s) in RCA: 47] [Impact Index Per Article: 23.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/20/2021] [Revised: 03/13/2022] [Indexed: 06/14/2023]
Abstract
Microneedles (MNs) are minimally invasive devices, which have gained extensive interest over the past decades in various fields including drug delivery, disease diagnosis, monitoring, and cosmetics. MN geometry and shape are key parameters that dictate performance and therapeutic efficacy, however, traditional fabrication methods, such as molding, may not be able to offer rapid design modifications. In this regard, the fabrication of MNs using 3D printing technology enables the rapid creation of complex MN prototypes with high accuracy and offers customizable MN devices with a desired shape and dimension. Moreover, 3D printing shows great potential in producing advanced transdermal drug delivery systems and medical devices by integrating MNs with a variety of technologies. This review aims to demonstrate the advantages of exploiting 3D printing technology as a new tool to microengineer MNs. Various 3D printing methods are introduced, and representative MNs manufactured by such approaches are highlighted in detail. The development of advanced MN devices is also included. Finally, clinical translation and future perspectives for the development of MNs using 3D printing are discussed.
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Affiliation(s)
- Usanee Detamornrat
- School of Pharmacy, Queen's University Belfast, Medical Biology Centre, 97 Lisburn Road, Belfast, BT9 7BL, UK
| | - Emma McAlister
- School of Pharmacy, Queen's University Belfast, Medical Biology Centre, 97 Lisburn Road, Belfast, BT9 7BL, UK
| | - Aaron R J Hutton
- School of Pharmacy, Queen's University Belfast, Medical Biology Centre, 97 Lisburn Road, Belfast, BT9 7BL, UK
| | - Eneko Larrañeta
- School of Pharmacy, Queen's University Belfast, Medical Biology Centre, 97 Lisburn Road, Belfast, BT9 7BL, UK
| | - Ryan F Donnelly
- School of Pharmacy, Queen's University Belfast, Medical Biology Centre, 97 Lisburn Road, Belfast, BT9 7BL, UK
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Clinical applications and prospects of 3D printing guide templates in orthopaedics. J Orthop Translat 2022; 34:22-41. [PMID: 35615638 PMCID: PMC9117878 DOI: 10.1016/j.jot.2022.03.001] [Citation(s) in RCA: 24] [Impact Index Per Article: 12.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Received: 01/14/2022] [Revised: 02/27/2022] [Accepted: 03/01/2022] [Indexed: 12/05/2022] Open
Abstract
Background With increasing requirements for medical effects, and huge differences among individuals, traditional surgical instruments are difficult to meet the patients' growing medical demands. 3D printing is increasingly mature, which connects to medical services critically as well. The patient specific surgical guide plate provides the condition for precision medicine in orthopaedics. Methods In this paper, a systematic review of the orthopedic guide template is presented, where the history of 3D-printing-guided technology, the process of guides, and basic clinical applications of orthopedic guide templates are described. Finally, the limitations of the template and possible future directions are discussed. Results The technology of 3D printing surgical templates is increasingly mature, standard, and intelligent. With the help of guide templates, the surgeon can easily determine the direction and depth of the screw path, and choose the angle and range of osteotomy, increasing the precision, safety, and reliability of the procedure in various types of surgeries. It simplifies the difficult surgical steps and accelerates the growth of young and mid-career physicians. But some problems such as cost, materials, and equipment limit its development. Conclusions In different fields of orthopedics, the use of guide templates can significantly improve surgical accuracy, shorten the surgical time, and reduce intraoperative bleeding and radiation. With the development of 3D printing, the guide template will be standardized and simplified from design to production and use. 3D printing guides will be further sublimated in the application of orthopedics and better serve the patients. The translational potential of this paper Precision, intelligence, and individuation are the future development direction of orthopedics. It is more and more popular as the price of printers falls and materials are developed. In addition, the technology of meta-universe, digital twin, and artificial intelligence have made revolutionary effects on template guides. We aim to summarize recent developments and applications of 3D printing guide templates for engineers and surgeons to develop more accurate and efficient templates.
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The Key Role of 3D Printing Technologies in the Further Development of Electrical Machines. MACHINES 2022. [DOI: 10.3390/machines10050330] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/10/2022]
Abstract
There is a strong general demand for the permanent improvement of electrical machines. Nowadays, these are at their near maximum potential, and even small further improvements can only be achieved with great effort and high cost. The single solution should be a paradigm shift in their development, by using radically new approaches to topology, materials, and fabrication. Therefore, the application of diverse 3D printing techniques for advanced fabrication in this field is inevitable. Therefore, these new approaches are receiving a great deal of attention among electrical machines designers. In the paper, the possible applications of these new fabrication technologies in the field of electrical machines are surveyed. The focus is set on emphasizing the advancement over the traditional manufacturing approaches.
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Grinschek F, Dübal S, Klahn C, Dittmeyer R. Einfluss des additiven Fertigungsverfahrens auf die Gestalt einer Mikrorektifikationsapparatur. CHEM-ING-TECH 2022. [DOI: 10.1002/cite.202200011] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
Affiliation(s)
- Fabian Grinschek
- Karlsruher Institut für Technologie (KIT) Institut für Mikroverfahrenstechnik (IMVT) Hermann-von-Helmholtz-Platz 1 76344 Eggenstein-Leopoldshafen Deutschland
| | - Sören Dübal
- Karlsruher Institut für Technologie (KIT) Institut für Mikroverfahrenstechnik (IMVT) Hermann-von-Helmholtz-Platz 1 76344 Eggenstein-Leopoldshafen Deutschland
| | - Christoph Klahn
- Karlsruher Institut für Technologie (KIT) Institute für Mechanische Verfahrenstechnik und Mechanik (MVM) Hermann-von-Helmholtz-Platz 1 76344 Eggenstein-Leopoldshafen Deutschland
| | - Roland Dittmeyer
- Karlsruher Institut für Technologie (KIT) Institut für Mikroverfahrenstechnik (IMVT) Hermann-von-Helmholtz-Platz 1 76344 Eggenstein-Leopoldshafen Deutschland
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Application of the Digital Workflow in Orofacial Orthopedics and Orthodontics: Printed Appliances with Skeletal Anchorage. APPLIED SCIENCES-BASEL 2022. [DOI: 10.3390/app12083820] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/04/2023]
Abstract
As digital workflows are gaining popularity, novel treatment options have also arisen in orthodontics. By using selective laser melting (SLM), highly customized 3D-printed appliances can be manufactured and combined with preformed components. When combined with temporary anchorage devices (TADs), the advantages of the two approaches can be merged, which might improve treatment efficacy, versatility, and patient comfort. This article summarizes state-of-the-art technologies and digital workflows to design and install 3D-printed skeletally anchored orthodontic appliances. The advantages and disadvantages of digital workflows are critically discussed, and examples for the clinical application of mini-implant and mini-plate borne appliances are demonstrated.
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Illi J, Bernhard B, Nguyen C, Pilgrim T, Praz F, Gloeckler M, Windecker S, Haeberlin A, Gräni C. Translating Imaging Into 3D Printed Cardiovascular Phantoms. JACC Basic Transl Sci 2022; 7:1050-1062. [PMID: 36337920 PMCID: PMC9626905 DOI: 10.1016/j.jacbts.2022.01.002] [Citation(s) in RCA: 11] [Impact Index Per Article: 5.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Received: 10/20/2021] [Revised: 12/03/2021] [Accepted: 01/03/2022] [Indexed: 11/27/2022]
Abstract
3D printed patient specific phantoms can visualize complex cardiovascular anatomy Common imaging modalities for 3D printing are CCT and CMR Material jetting/PolyJet and stereolithography are widely used printing techniques Standardized validation is warranted to compare different 3D printing technologies
Translation of imaging into 3-dimensional (3D) printed patient-specific phantoms (3DPSPs) can help visualize complex cardiovascular anatomy and enable tailoring of therapy. The aim of this paper is to review the entire process of phantom production, including imaging, materials, 3D printing technologies, and the validation of 3DPSPs. A systematic review of published research was conducted using Embase and MEDLINE, including studies that investigated 3DPSPs in cardiovascular medicine. Among 2,534 screened papers, 212 fulfilled inclusion criteria and described 3DPSPs as a valuable adjunct for planning and guiding interventions (n = 108 [51%]), simulation of physiological or pathological conditions (n = 19 [9%]), teaching of health care professionals (n = 23 [11%]), patient education (n = 3 [1.4%]), outcome prediction (n = 6 [2.8%]), or other purposes (n = 53 [25%]). The most common imaging modalities to enable 3D printing were cardiac computed tomography (n = 131 [61.8%]) and cardiac magnetic resonance (n = 26 [12.3%]). The printing process was conducted mostly by material jetting (n = 54 [25.5%]) or stereolithography (n = 43 [20.3%]). The 10 largest studies that evaluated the geometric accuracy of 3DPSPs described a mean bias <±1 mm; however, the validation process was very heterogeneous among the studies. Three-dimensional printed patient-specific phantoms are highly accurate, used for teaching, and applied to guide cardiovascular therapy. Systematic comparison of imaging and printing modalities following a standardized validation process is warranted to allow conclusions on the optimal production process of 3DPSPs in the field of cardiovascular medicine.
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Effect of Laser Remelting Strategy on the Forming Ability of Cemented Carbide Fabricated by Laser Powder Bed Fusion (L-PBF). MATERIALS 2022; 15:ma15072380. [PMID: 35407713 PMCID: PMC8999759 DOI: 10.3390/ma15072380] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/25/2022] [Revised: 03/19/2022] [Accepted: 03/22/2022] [Indexed: 11/17/2022]
Abstract
Due to the high degree of design freedom and rapid prototyping, laser powder bed fusion (L-PBF) presents a great advantage in the super-hard cemented carbide compared with conventional methods. However, optimizing processing parameters to improve the relative density and surface roughness is still a challenge for cemented carbide fabricated by L-PBF. For this, the effect of the remelting strategy on the forming quality of the L-PBF processed cemented carbide was studied in this article, aiming to explore a suitable process window. The surface quality, relative density, microstructure, and microhardness of the cemented carbide parts fabricated under a single melting and remelting strategy were compared. The results showed that the remelting strategy could efficiently improve the specimens’ surface quality and relative density. Besides, the cracks were not obviously aggravated, and the WC grains could distribute more homogeneously on the binder matrix under the remelting strategy. Therefore, the microhardness showed an improvement compared to the single melting strategy.
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Additive manufacturing of titanium-based alloys- A review of methods, properties, challenges, and prospects. Heliyon 2022; 8:e09041. [PMID: 35299605 PMCID: PMC8920912 DOI: 10.1016/j.heliyon.2022.e09041] [Citation(s) in RCA: 10] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/01/2021] [Revised: 12/12/2021] [Accepted: 02/28/2022] [Indexed: 11/20/2022] Open
Abstract
The development of materials for biomedical, aerospace, and automobile industries has been a significant area of research in recent years. Various metallic materials, including steels, cast iron, nickel-based alloys, and other metals with exceptional mechanical properties, have been reportedly utilized for fabrication in these industries. However, titanium and its alloys have proven to be outstanding due to their enhanced properties. The β-titanium alloys with reduced modulus compared with the human bone have found more usage in the biomedical industry. In contrast, the α and α+β titanium alloys are more utilized to fabricate parts in the automobile and aerospace industries due to their relatively lightweight. Amongst the numerous additive manufacturing (AM) techniques, selective laser and electron beam melting techniques are frequently used for the fabrication of metallic components due to the full densification and high dimensional accuracy they offer. This paper reviews and discusses the different types of AM techniques, attention is also drawn to the properties and challenges associated with additively manufactured titanium -based alloys. The outcome from this study shows that 3D printed titanium and titanium-alloys exhibit huge prospects for various applications in the medical and aerospace industries. Also, laser-assisted 3D technologies were found to be the most effective AM method for achieving enhanced or near-full densification.
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Simeonov Y, Weber U, Schuy C, Engenhart-Cabillic R, Penchev P, Flatten V, Zink K. Development, Monte Carlo simulations and experimental evaluation of a 3D range-modulator for a complex target in scanned proton therapy. Biomed Phys Eng Express 2022; 8. [PMID: 35226887 DOI: 10.1088/2057-1976/ac5937] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/03/2022] [Accepted: 02/28/2022] [Indexed: 01/02/2023]
Abstract
The purpose of this work was to develop and manufacture a 3D range-modulator (3D RM) for a complex target contour for scanned proton therapy. The 3D RM is considered to be a viable technique for the very fast dose application in patient-specific tumors with only one fixed energy. The RM was developed based on a tumor from a patient CT and manufactured with high-quality 3D printing techniques with both polymer resin and aluminum. Monte Carlo simulations were utilized to investigate its modulating properties and the resulting dose distribution. Additionally, the simulation results were validated with measurements at the Marburg Ion-Beam Therapy Centre. For this purpose, a previously developed water phantom was used to conduct fast, automated high-resolution dose measurements. The results show a very good agreement between simulations and measurements and indicate that highly homogeneous dose distributions are possible. The delivered dose is conformed to the distal as well as to the proximal edge of the target. The 3D range-modulator concept combines a high degree of dose homogeneity and conformity, comparable to standard IMPT with very short irradiation times, promising clinically applicable dose distributions for lung and/or FLASH treatment, comparable and competitive to those from conventional irradiation techniques.
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Affiliation(s)
- Yuri Simeonov
- University of Applied Sciences, Institute of Medical Physics and Radiation Protection (IMPS), Giessen, Germany.,Philipps-University, Marburg, Germany
| | - Uli Weber
- GSI Helmholtzzentrum für Schwerionenforschung GmbH, Biophysics division, Darmstadt, Germany
| | - Christoph Schuy
- GSI Helmholtzzentrum für Schwerionenforschung GmbH, Biophysics division, Darmstadt, Germany
| | - Rita Engenhart-Cabillic
- University Medical Center Giessen-Marburg, Department of Radiotherapy and Radiooncology, Marburg, Germany.,Marburg Ion Beam Therapy Center (MIT), Marburg, Germany
| | - Petar Penchev
- University of Applied Sciences, Institute of Medical Physics and Radiation Protection (IMPS), Giessen, Germany.,Philipps-University, Marburg, Germany
| | - Veronika Flatten
- University of Applied Sciences, Institute of Medical Physics and Radiation Protection (IMPS), Giessen, Germany.,Philipps-University, Marburg, Germany.,University Medical Center Giessen-Marburg, Department of Radiotherapy and Radiooncology, Marburg, Germany.,Marburg Ion Beam Therapy Center (MIT), Marburg, Germany
| | - Klemens Zink
- University of Applied Sciences, Institute of Medical Physics and Radiation Protection (IMPS), Giessen, Germany.,University Medical Center Giessen-Marburg, Department of Radiotherapy and Radiooncology, Marburg, Germany.,Marburg Ion Beam Therapy Center (MIT), Marburg, Germany
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Cho SY, Ho DH, Choi YY, Lim S, Lee S, Suk JW, Jo SB, Cho JH. A general fruit acid chelation route for eco-friendly and ambient 3D printing of metals. Nat Commun 2022; 13:104. [PMID: 35256609 PMCID: PMC8901924 DOI: 10.1038/s41467-021-27730-6] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/08/2021] [Accepted: 11/29/2021] [Indexed: 11/09/2022] Open
Abstract
AbstractRecent advances in metal additive manufacturing (AM) have provided new opportunities for prompt designs of prototypes and facile personalization of products befitting the fourth industrial revolution. In this regard, its feasibility of becoming a green technology, which is not an inherent aspect of AM, is gaining more interests. A particular interest in adapting and understanding of eco-friendly ingredients can set its important groundworks. Here, we demonstrate a water-based solid-phase binding agent suitable for binder jetting 3D printing of metals. Sodium salts of common fruit acid chelators form stable metal-chelate bridges between metal particles, enabling elaborate 3D printing of metals with improved strengths. Even further reductions in the porosity between the metal particles are possible through post-treatments. A compatibility of this chelation chemistry with variety of metals is also demonstrated. The proposed mechanism for metal 3D printing can open up new avenues for consumer-level personalized 3D printing of metals.
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Computer vision-aided bioprinting for bone research. Bone Res 2022; 10:21. [PMID: 35217642 PMCID: PMC8881598 DOI: 10.1038/s41413-022-00192-2] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/09/2021] [Revised: 12/10/2021] [Accepted: 12/21/2021] [Indexed: 02/08/2023] Open
Abstract
Bioprinting is an emerging additive manufacturing technology that has enormous potential in bone implantation and repair. The insufficient accuracy of the shape of bioprinted parts is a primary clinical barrier that prevents widespread utilization of bioprinting, especially for bone design with high-resolution requirements. During the last five years, the use of computer vision for process control has been widely practiced in the manufacturing field. Computer vision can improve the performance of bioprinting for bone research with respect to various aspects, including accuracy, resolution, and cell survival rate. Hence, computer vision plays a substantial role in addressing the current defect problem in bioprinting for bone research. In this review, recent advances in the application of computer vision in bioprinting for bone research are summarized and categorized into three groups based on different defect types: bone scaffold process control, deep learning, and cell viability models. The collection of printing parameters, data processing, and feedback of bioprinting information, which ultimately improves printing capabilities, are further discussed. We envision that computer vision may offer opportunities to accelerate bioprinting development and provide a new perception for bone research.
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Chavez LA, Ibave P, Hassan MS, Hall‐Sanchez SE, Billah KMM, Leyva A, Marquez C, Espalin D, Torres S, Robison T, Lin Y. Low‐temperature
selective laser sintering
3D
printing of
PEEK‐Nylon
blends: Impact of thermal
post‐processing
on mechanical properties and thermal stability. J Appl Polym Sci 2022. [DOI: 10.1002/app.52290] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
Affiliation(s)
- Luis A. Chavez
- Department of Mechanical Engineering The University of Texas at El Paso El Paso Texas USA
- W.M. Keck Center for 3D Innovation The University of Texas at El Paso El Paso Texas USA
| | - Paulina Ibave
- Department of Mechanical Engineering The University of Texas at El Paso El Paso Texas USA
- W.M. Keck Center for 3D Innovation The University of Texas at El Paso El Paso Texas USA
| | - Md Sahid Hassan
- Department of Mechanical Engineering The University of Texas at El Paso El Paso Texas USA
- W.M. Keck Center for 3D Innovation The University of Texas at El Paso El Paso Texas USA
| | - Samuel E. Hall‐Sanchez
- Department of Mechanical Engineering The University of Texas at El Paso El Paso Texas USA
- W.M. Keck Center for 3D Innovation The University of Texas at El Paso El Paso Texas USA
| | - Kazi Md Masum Billah
- Mechanical Engineering Program University of Houston‐Clear Lake Houston Texas USA
| | - Alba Leyva
- Department of Mechanical Engineering The University of Texas at El Paso El Paso Texas USA
- W.M. Keck Center for 3D Innovation The University of Texas at El Paso El Paso Texas USA
| | - Cory Marquez
- Department of Mechanical Engineering The University of Texas at El Paso El Paso Texas USA
- W.M. Keck Center for 3D Innovation The University of Texas at El Paso El Paso Texas USA
| | - David Espalin
- Department of Mechanical Engineering The University of Texas at El Paso El Paso Texas USA
- W.M. Keck Center for 3D Innovation The University of Texas at El Paso El Paso Texas USA
| | - Sabrina Torres
- National Security Campus operated by Honeywell Kansas City Missouri USA
| | - Thomas Robison
- National Security Campus operated by Honeywell Kansas City Missouri USA
| | - Yirong Lin
- Department of Mechanical Engineering The University of Texas at El Paso El Paso Texas USA
- W.M. Keck Center for 3D Innovation The University of Texas at El Paso El Paso Texas USA
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Main Applications and Recent Research Progresses of Additive Manufacturing in Dentistry. BIOMED RESEARCH INTERNATIONAL 2022; 2022:5530188. [PMID: 35252451 PMCID: PMC8894006 DOI: 10.1155/2022/5530188] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 01/20/2021] [Revised: 12/16/2021] [Accepted: 01/28/2022] [Indexed: 12/13/2022]
Abstract
In recent ten years, with the fast development of digital and engineering manufacturing technology, additive manufacturing has already been more and more widely used in the field of dentistry, from the first personalized surgical guides to the latest personalized restoration crowns and root implants. In particular, the bioprinting of teeth and tissue is of great potential to realize organ regeneration and finally improve the life quality. In this review paper, we firstly presented the workflow of additive manufacturing technology. Then, we summarized the main applications and recent research progresses of additive manufacturing in dentistry. Lastly, we sketched out some challenges and future directions of additive manufacturing technology in dentistry.
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