Biodegradable WE43 Magnesium Alloy Produced by Selective Laser Melting: Mechanical Properties, Corrosion Behavior, and In-Vitro Cytotoxicity

Biocompatibility and osteogenic capacity of additively manufactured biodegradable porous WE43 scaffolds: An in vivo study in a canine model

Magnesium is the most promising absorbable metallic implant material for bone regeneration and alloy WE43 is already FDA approved for cardiovascular applications. This study investigates the cyto- and biocompatibility of novel additively manufactured (AM) porous WE43 scaffolds as well as their osteogenic potential and degradation characteristics in an orthotopic canine bone defect model. The cytocompatibility was demonstrated using modified ISO 10993-conform extract-based indirect and direct assays, respectively. Additionally, degradation rates of WE43 scaffolds were quantified in vitro prior to absorption tests in vivo. Complete blood cell counts, blood biomarker analyses, blood trace element analyses as well as multi-organ histopathology demonstrated excellent biocompatibility of porous y WE43 scaffolds for bone defect repair. Micro-CT analyses further showed a relatively higher absorption rate during the initial four weeks upon implantation (i.e., 36 % ± 19 %) than between four and 12 weeks (41 % ± 14 %), respectively. Of note, the porous WE43 implants were surrounded by newly formed bony tissue as early as four weeks after implantation when unmineralized trabecular ingrowth was detected. After 12 weeks, a substantial amount of mineralized bone was detected inside and around the gradually disappearing implants. This first study on AM porous WE43 implants in canine bone defects demonstrates the potential of this alloy for in vivo applications in humans. Our data further underscore the need to control initial bulk absorption kinetics through surface modifications.

The Characterization of a Biodegradable Mg Alloy after Powder Bed Fusion with Laser Beam/Metal Processing for Custom Shaped Implants

A new Mg-Zn-Zr-Ca alloy in a powder state, intended to be used for custom shaped implants, was obtained via a mechanical alloying method from pure elemental powder. Further, the obtained powder alloy was processed by a PBF-LB/M (powder bed fusion with laser beam/of metal) procedure to obtain additive manufactured samples for small biodegradable implants. A series of microstructural, mechanical and corrosion analyses were performed. The SEM (scanning electron microscopy) analysis of the powder alloy revealed a good dimensional homogeneity, with a uniform colour, no agglutination and almost rounded particles, suitable for the powder bed fusion procedure. Further, the PBF-LB/M samples revealed a robust and unbreakable morphology, with a suitable porosity (that can reproduce that of cortical bone) and without an undesirable balling effect. The tested Young's modulus of the PBF-LB/M samples, which was 42 GPa, is close to that of cortical bone, 30 GPa. The corrosion tests that were performed in PBS (Phosphate-buffered saline) solution, with three different pH values, show that the corrosion parameters have a satisfactory evolution comparative to the commercial ZK 60 alloy.

Combination of Scanning Strategies and Optimization Experiments for Laser Beam Powder Bed Fusion of Ti-6Al-4V Titanium Alloys

This paper studies the effects of different combinations of scanning strategies between layers on the surface quality, tensile properties, and microstructure of samples in a laser beam powder bed fusion (L-PBF) formation experiment of Ti-6Al-4V titanium alloy. The purpose of this experiment was to improve the comprehensive performance of the piece by selecting the optimal combination of scanning strategies. The results show that the surface roughness of the L-PBF specimen was the lowest under the combination of the CHESS scanning strategy, reaching 14 μm. The surface hardness of the samples was generally higher with the LINE scanning strategy and the angle offset of 90°, reaching 409 HV. The overall density of the samples was higher under the combination of CHESS scanning strategies, reaching 99.88%. Among them, the CHESS&45° sample had the best comprehensive properties, with a density of 99.85%, a tensile strength of up to 1125 MPa, a yield strength of 912 MPa, and an elongation of 8.2%. The fractured form was a ductile fracture, with many dimple structures. Compared with the CHESS scanning strategy, the tensile properties of the CHESS&45° samples were improved by 12.8%. The microstructure of the L-PBF sample was mainly composed of the primary β phase and α’ martensite phase. The upper surface of the CHESS scanning strategy combination sample had a clear melt channel, and the distribution of each phase was uniform. A certain number of columnar β crystals were distributed in the longitudinal section of the sample, which was paralleled to the build direction. The columnar β crystals of CHESS&45° were relatively coarse, which enhanced the tensile properties of the sample.