A 3D-Printed Ultra-Low Young's Modulus β-Ti Alloy for Biomedical Applications

The role of internal architecture in producing high-strength 3D printed cobalt-chromium objects

PURPOSE

The objectives of the current study were to estimate the influence of self-reinforced hollow structures with a graded density on the dimensional accuracy, weight, and mechanical properties of Co-Cr objects printed with the direct metal laser sintering (DMLS) technique.

MATERIALS AND METHODS

Sixty-five dog-bone samples were manufactured to evaluate the dimensional accuracy of printing, weight, and tensile properties of DMLS printed Co-Cr. They were divided into Group 1 (control) (n = 5), Group 2, 3, and 4 with incorporated hollow structures based on (spherical, elliptical, and diamond) shapes; they were subdivided into subgroups (n = 5) according to the volumetric reduction (10%, 15%, 20% and 25%). Radiographic imaging and microscopic analysis of the fractographs were conducted to validate the created geometries; the dimensional accuracy, weight, yield tensile strength, and modulus of elasticity were calculated. The data were estimated by one-way ANOVA and Duncan's tests at P < .05.

RESULTS

The accuracy test showed an insignificant difference in the x, y, z directions in all printed groups. The weight was significantly reduced proportionally to the reduced volume fraction. The yield strength and elastic modulus of the control group and Group 2 at 10% volume reduction were comparable and significantly higher than the other subgroups.

CONCLUSION

The printing accuracy was not affected by the presence or type of the hollow geometry. The weight of Group 2 at 10% reduction was significantly lower than that of the control group. The yield strength and elastic modulus of the Group 2 at a 10% reduction showed means equivalent to the compact objects and were significantly higher than other subgroups.

The influence of internally architected voids in the creation of high-strength, low-weight 3D-printed cobalt-chromium prototypes

Background

The additive manufacturing technology made the topology optimization technique feasible. This technique can indefinitely reduce the weight of the printed items with a promising increase in the mechanical properties of that item.

Materials and Methods

In the current experimental study, 50 samples were fabricated for a 3-point bending test. They were divided into (n = 5) as a control Group 1 free of internal geometries, (n = 15) for each of Groups 2-4, and they were subdivided into (n = 5) for each percentage of reduction per volume (10%, 15%, and 20%). Spherical, ovoid, and diamond shapes were each group's fundamental geometries, respectively. Cylindrical tunnels connected the voids in each group. Radiographic images were performed to validate the created geometries, the weight was measured, and flexural strength and modulus of elasticity were calculated. Data were analyzed by one-way ANOVA and Duncan's post hoc tests at P < 0.05.

Results

The weight results showed a significant reduction in mass. The flexural strength of Group 2 at a 10% reduction per volume had the highest mean significantly without compromising the elastic modulus. In comparison, the means of group 4 at 20% reduction showed the lowest level of toughness.

Conclusion

The weight was reduced according to the reduction percentage. The flexural strength of Group 2 at a 10% reduction showed the highest degree of toughness among all groups. The void shape and density influenced the mechanical properties tested.

Manufacturability of functionally graded porous β-Ti21S auxetic architected biomaterials produced by laser powder bed fusion: Comparison between 2D and 3D metrological characterization

Functionally graded porous structures (FGPSs) are attracting increasing interest in the manufacture of prostheses that benefit from lower stiffness and optimized pore size for osseointegration. In this work, we explore the possibility of employing FGPSs with auxetic unit cells. Their negative Poisson's ratio was exploited to reduce the loss of connection between prosthesis and bone usually occurring in standard implant loaded under tension and therefore undergoing lateral shrinking. In addition, to further improve osseointegration and mitigate stress shielding effects, auxetic FGPSs were fabricated in this work using a novel β-Ti21S alloy characterized by a lower Young's modulus compared to traditional α + β Ti alloys. Specifically, two different auxetic FGPSs with aspect ratio equal to 1.5 and angle θ of 15° and 25° with a relative density (ρ_r) gradient of 0.34, 0.49, 0.66 and of 0.40, 0.58, 0.75 were designed and printed by laser powder bed fusion. The 2D and 3D metrological characterization of the as-manufactured structures was compared with the design. 2D metrological characterization was carried out using scanning electron microscopy analysis, while for the 3D characterization, X-ray micro-CT imaging was used. An undersizing of the pore size and strut thickness in the as-manufactured sample was observed in both auxetic FGPSs. A maximum difference in the strut thickness of -14 and -22% was obtained in the auxetic structure with θ = 15° and 25°, respectively. On the contrary, a pore undersizing of -19% and -15% was evaluated in auxetic FGPS with θ = 15° and 25°, respectively. Compression mechanical tests allowed to determine stabilized elastic modulus of around 4 GPa for both FGPSs. Homogenization method and analytical equation were used and the comparison with experimental data highlights a good agreement of around 4% and 24% for θ = 15° and 25°, respectively.

Progress in partially degradable titanium-magnesium composites used as biomedical implants

Titanium-magnesium composites have gained increasing attention as a partially degradable biomaterial recently. The titanium-magnesium composite combines the bioactivity of magnesium and the good mechanical properties of titanium. Here, we discuss the limitations of conventional mechanically alloyed titanium-magnesium alloys for bioimplants, in addition we summarize three suitable methods for the preparation of titanium-magnesium composites for bioimplants by melt: infiltration casting, powder metallurgy and hot rotary swaging, with a description of the advantages and disadvantages of all three methods. The titanium-magnesium composites were comprehensively evaluated in terms of mechanical properties and degradation behavior. The feasibility of titanium-magnesium composites as bio-implants was reviewed. In addition, the possible future development of titanium-magnesium composites was discussed. Thus, this review aims to build a conceptual and practical toolkit for the design of titanium-magnesium composites capable of local biodegradation.

Cantilevers: Multi-Tool in Orthodontic Treatment

This review aims to discuss and illustrate various uses of cantilevers to solve multiple clinical issues and prove their versatility. Cantilevers are commonly used in the segmented arch technique, and they can be designed to solve various clinical problems with highly predictable results. Its design and shape can modify the various combinations of vertical and horizontal forces. The novel trend is to combine cantilevers with skeletal anchorage. Cantilevers offer a very simple and statically determined force system. The advantage is the control over side effects, which normally occur on the anchor teeth and the occlusion. The disadvantages include possible side effects on the anchorage unit, when the anchorage is poorly controlled. The review highlights the clear benefits of cantilever use in complex corrections of single teeth, segments, and entire arch with a diminished effect on the dentition, also with the use of skeletal anchorage. With their simple and easily tailored design, these springs can be called an orthodontic multi-tool.

Innovative Design Methodology for Patient-Specific Short Femoral Stems

The biomechanical performance of hip prostheses is often suboptimal, which leads to problems such as strain shielding, bone resorption and implant loosening, affecting the long-term viability of these implants for articular repair. Different studies have highlighted the interest of short stems for preserving bone stock and minimizing shielding, hence providing an alternative to conventional hip prostheses with long stems. Such short stems are especially valuable for younger patients, as they may require additional surgical interventions and replacements in the future, for which the preservation of bone stock is fundamental. Arguably, enhanced results may be achieved by combining the benefits of short stems with the possibilities of personalization, which are now empowered by a wise combination of medical images, computer-aided design and engineering resources and automated manufacturing tools. In this study, an innovative design methodology for custom-made short femoral stems is presented. The design process is enhanced through a novel app employing elliptical adjustment for the quasi-automated CAD modeling of personalized short femoral stems. The proposed methodology is validated by completely developing two personalized short femoral stems, which are evaluated by combining in silico studies (finite element method (FEM) simulations), for quantifying their biomechanical performance, and rapid prototyping, for evaluating implantability.

A state-of-the-art review of the fabrication and characteristics of titanium and its alloys for biomedical applications

Abstract

Commercially pure titanium and titanium alloys have been among the most commonly used materials for biomedical applications since the 1950s. Due to the excellent mechanical tribological properties, corrosion resistance, biocompatibility, and antibacterial properties of titanium, it is getting much attention as a biomaterial for implants. Furthermore, titanium promotes osseointegration without any additional adhesives by physically bonding with the living bone at the implant site. These properties are crucial for producing high-strength metallic alloys for biomedical applications. Titanium alloys are manufactured into the three types of α, β, and α + β. The scientific and clinical understanding of titanium and its potential applications, especially in the biomedical field, are still in the early stages. This review aims to establish a credible platform for the current and future roles of titanium in biomedicine. We first explore the developmental history of titanium. Then, we review the recent advancement of the utility of titanium in diverse biomedical areas, its functional properties, mechanisms of biocompatibility, host tissue responses, and various relevant antimicrobial strategies. Future research will be directed toward advanced manufacturing technologies, such as powder-based additive manufacturing, electron beam melting and laser melting deposition, as well as analyzing the effects of alloying elements on the biocompatibility, corrosion resistance, and mechanical properties of titanium. Moreover, the role of titania nanotubes in regenerative medicine and nanomedicine applications, such as localized drug delivery system, immunomodulatory agents, antibacterial agents, and hemocompatibility, is investigated, and the paper concludes with the future outlook of titanium alloys as biomaterials.

Graphic abstract

Reconstruction of bilateral ramus-condyle unit defect using custom titanium prosthesis with preservation of both condyles

BACKGROUND

Novel technologies for management and reconstruction of complex bony defects regarding both function and facial appearance are interestingly used in maxillofacial surgery. In the current study, we demonstrated reconstruction of a bilateral ramus-condyle unit (RCU) defect while preserving both condyles by a novel designed titanium prosthesis using virtual surgical planning (VSP), computer-aided design and manufacturing (CAD/CAM), and Selective Laser Melting (SLM) technologies.

MATERIALS AND METHODS

A 3D customized titanium prosthesis was designed for a 49 -year-old patient with bilateral mandibular aggressive central giant cell granuloma (CGCG) according to mandibular normal anatomy and structure while preserving bilateral intact condyles. Finite element study was performed to investigate the effects of new design strength and the stress shielding phenomenon. The design of macro-pores inside the body of prosthesis allowed it to act as a scaffold for bone tissue engineering under load bearing conditions.

RESULTS

Analysis of the strength and stress shielding phenomenon demonstrated favorable outcomes regarding the novel design. For instance, there was no stress shielding in any of the preserved condyles with regard to the size and distribution of stresses. Also, the stress distribution around the pores showed that these pores had no effect on the strength of the prosthesis. Thirty month follow-ups after reconstruction of bilateral RCU defect showed normal jaw function with a favorable facial appearance and mandibular contour.

CONCLUSION

We design a novel patient-specific prosthesis with desirable biomechanical features for reconstruction of bilateral RCU defect after resection of the benign tumor with preservation of bilateral intact condyles.

Upper Limb Design of an Anthropometric Crash Test Dummy for Low Impact Rates

The article presents the design of the upper limb joints of an anthropometric dummy intended for rear crash tests for low impact speeds. These joints represent the connection of the hand to the forearm, the forearm to the arm, and the arm to the shoulder. The designed joint is adapted to the construction of a dummy representing the 50th percentile male. The joints currently used on Hybrid III dummies require calibration after each crash test. The construction of the new joint ensures the appropriate strength of individual joint elements and the repeatable value of the joint characteristics without the need for frequent calibrations. The designed joints have the ability to set a variable stiffness characteristic, thanks to which it is possible to use this joint universally in dummies representing populations of other percentile sizes. The range of movement of the joints has been selected to reflect the range of mobility of the upper limb of an adult. The characteristics of the joints were compared with those used in the joints of the Hybrid III 50 percentile male dummy. Moreover, it should be noted that the constructed joints of the upper limb are made by hand; therefore, their comparison with the Hybrid III dummy shows some deviations in the moments of resistance. Making the joints with a 3D printer, taking into account the appropriate material, will ensure greater accuracy and will also result in joining the individual elements of the joint into a whole. The obtained results show slight differences between the moment of resistance in the joints of the constructed anthropometric dummy compared to the hybrid III dummy.

Recent Development in Beta Titanium Alloys for Biomedical Applications

β-type titanium (Ti) alloys have attracted a lot of attention as novel biomedical materials in the past decades due to their low elastic moduli and good biocompatibility. This article provides a broad and extensive review of β-type Ti alloys in terms of alloy design, preparation methods, mechanical properties, corrosion behavior, and biocompatibility. After briefly introducing the development of Ti and Ti alloys for biomedical applications, this article reviews the design of β-type Ti alloys from the perspective of the molybdenum equivalency (Moeq) method and DV-Xα molecular orbital method. Based on these methods, a considerable number of β-type Ti alloys are developed. Although β-type Ti alloys have lower elastic moduli compared with other types of Ti alloys, they still possess higher elastic moduli than human bones. Therefore, porous β-type Ti alloys with declined elastic modulus have been developed by some preparation methods, such as powder metallurgy, additive manufacture and so on. As reviewed, β-type Ti alloys have comparable or even better mechanical properties, corrosion behavior, and biocompatibility compared with other types of Ti alloys. Hence, β-type Ti alloys are the more suitable materials used as implant materials. However, there are still some problems with β-type Ti alloys, such as biological inertness. As such, summarizing the findings from the current literature, suggestions forβ-type Ti alloys with bioactive coatings are proposed for the future development.

Three-Jet Powder Flow and Laser–Powder Interaction in Laser Melting Deposition: Modelling Versus Experimental Correlations

Powder flow and temperature distribution are recognized as essential factors in the laser melting deposition (LMD) process, which affect not only the layer formation but also its characteristics. In this study, two mathematical models were developed. Initially, the three-jet powder flow in the Gaussian shape was simulated for the LMD process. Next, the Gaussian powder flow was coaxially added along with the moving laser beam to investigate the effect of powder flow on temperature distribution at the substrate. The powder particles’ inflight and within melt-pool heating times were controlled to avoid vapors or plasma formation due to excessive heat. Computations were carried out via MATLAB software. A high-speed imaging camera was used to monitor the powder stream distribution, experimentally, while temperature distribution results were compared with finite element simulations and experimental analyses. A close correlation was observed among analytical computation, numerical simulations, and experimental results. An investigation was conducted to investigate the effect of the focal point position on powder stream distribution. It was found that the focal point position plays a key role in determining the shape of the powder stream, such that an increment in the distance from the focus point will gradually transform the powder stream from the Gaussian to Transition, and from the Transition to Annular streams. By raising the powder flow rate, the attenuation ratio prevails in the LMD process, hence, decreasing the laser energy density arriving at the substrate. The computations indicate that, if the particle’s heating temperature surpasses the boiling point, a strong possibility exists for vapors and plasma formation. Consequently, an excessive amount of laser energy is absorbed by the produced vapors and plasma, thus impeding the deposition process.