Additive Manufacturing of Orthopedic Implants

2018 ◽  
pp. 21-55 ◽  
Author(s):  
Maryam Tilton ◽  
Gregory S. Lewis ◽  
Guha P. Manogharan
Pharmaceutics ◽  
2021 ◽  
Vol 13 (5) ◽  
pp. 724
Author(s):  
Amilton Iatecola ◽  
Guilherme Arthur Longhitano ◽  
Luiz Henrique Martinez Antunes ◽  
André Luiz Jardini ◽  
Emilio de Castro Miguel ◽  
...  

Cobalt-base alloys (Co-Cr-Mo) are widely employed in dentistry and orthopedic implants due to their biocompatibility, high mechanical strength and wear resistance. The osseointegration of implants can be improved by surface modification techniques. However, complex geometries obtained by additive manufacturing (AM) limits the efficiency of mechanical-based surface modification techniques. Therefore, plasma immersion ion implantation (PIII) is the best alternative, creating nanotopography even in complex structures. In the present study, we report the osseointegration results in three conditions of the additively manufactured Co-Cr-Mo alloy: (i) as-built, (ii) after PIII, and (iii) coated with titanium (Ti) followed by PIII. The metallic samples were designed with a solid half and a porous half to observe the bone ingrowth in different surfaces. Our results revealed that all conditions presented cortical bone formation. The titanium-coated sample exhibited the best biomechanical results, which was attributed to the higher bone ingrowth percentage with almost all medullary canals filled with neoformed bone and the pores of the implant filled and surrounded by bone ingrowth. It was concluded that the metal alloys produced for AM are biocompatible and stimulate bone neoformation, especially when the Co-28Cr-6Mo alloy with a Ti-coated surface, nanostructured and anodized by PIII is used, whose technology has been shown to increase the osseointegration capacity of this implant.


2020 ◽  
Vol 134 ◽  
pp. 106208
Author(s):  
F. Bartolomeu ◽  
M.M. Costa ◽  
N. Alves ◽  
G. Miranda ◽  
F.S. Silva

2020 ◽  
Vol 1012 ◽  
pp. 343-348 ◽  
Author(s):  
R.B. Falcão ◽  
E. Sallica-Leva ◽  
D.L. Bayerlein ◽  
J.B. Ferreira Neto ◽  
F.J.G. Landgraf

In this work, the hydride-dehydride process (HDH) parameters to obtain Nb47Ti and Ti13Nb13Zr alloys powders were investigated, aiming the production of orthopedic implants by additive manufacturing (AM). Nb47Ti and Ti13Nb13Zr alloys were previously obtained by electron beam melting furnace (EBMF). During the hydriding step, the alloys were heated at two activation temperatures, 800 and 1000 °C, under constant hydrogen pressure (1.8 bar), for 40 min followed by a controlled cooling rate step (2 °C/min). The hydride alloys were milled in a ring-type mill, for milling times ranging from 2 to 6 min, until to achieve the required particle size range (between 15 and 45 μm). The dehydriding step of the alloys was carried out under high vacuum at 700 °C for times up to 5 h. The alloys treated under distinct HDH steps were characterized by X-ray diffraction, scanning electron microscopy, dynamic image analysis, inert gas fusion and gravimetry. The alloys hydrides (δTiHx phase) were detected in both investigated activation temperatures, with hydrogen (H) contents up to 3.04 and 3.62 wt.% for the Nb47Ti and Ti13Nb13Zr alloys, respectively. During the hydriding step it was also observed a significant increase of nitrogen (N) and oxygen (O) contents regarding he as-cast alloys. The Nb47Ti alloy showed a lower embrittlement degree than the Ti13Nb13Zr alloy, resulting in higher milling times to reach the required particle size distribution. The higher oxygen pick up was observed during the milling step. After the dehydriding step, the HDH powders showed H contents lower than 0.01 wt.%, beside a significant N decreasing. Particles with irregular (or angular) shapes were obtained. However, the particle size was in the required range.


2019 ◽  
Vol 19 (02) ◽  
pp. 1940014
Author(s):  
PRIMASARI WARDHANI ◽  
PEI-I TSAI ◽  
PEI-YU CHEN ◽  
YU-YOU CHEN ◽  
CHING-CHI HSU

Total ankle replacement (TAR) surgery is one of the useful methods to treat ankle arthritis. Selective laser melting that is an additive manufacturing (AM) technique has made it possible to fabricate orthopedic implants. However, there are rare studies to analyze AM implants using finite element method. Thus, the purpose of this study was to investigate the effect of the various porous designs with three types of tibial shapes for five ankle postures using three-dimensional (3D) human lower extremity models. The variable-axis-mobile-bearing (VAMB) TAR models were developed in one solid TAR design and three porous TAR designs on the tibial and talar components. Additionally, three shape designs (curved, flat, and tilted) of the tibial component were also evaluated. Each TAR design was assembled on the human lower extremity model with standing, inversion, eversion, plantar flexion, and dorsiflexion ankle postures. The results showed that there was a minor effect among the solid and porous TAR designs on the implant stability, the bone stress, and the implant stress. However, those performances in the plantar flexion were significantly reduced compared to that in the other ankle postures. Although the porous TAR designs have a higher risk of implant failure and bone breakage, it may have better bone-implant bonding ability. This study could help engineers and surgeons to understand the design rationale and biomechanics of AM-based TAR devices.


Materials ◽  
2019 ◽  
Vol 12 (20) ◽  
pp. 3361 ◽  
Author(s):  
Muhammad Jamshaid Zafar ◽  
Dongbin Zhu ◽  
Zhengyan Zhang

Bioceramics have frequent use in functional restoration of hard tissues to improve human well-being. Additive manufacturing (AM) also known as 3D printing is an innovative material processing technique extensively applied to produce bioceramic parts or scaffolds in a layered perspicacious manner. Moreover, the applications of additive manufacturing in bioceramics have the capability to reliably fabricate the commercialized scaffolds tailored for practical clinical applications, and the potential to survive in the new era of effective hard tissue fabrication. The similarity of the materials with human bone histomorphometry makes them conducive to use in hard tissue engineering scheme. The key objective of this manuscript is to explore the applications of bioceramics-based AM in bone tissue engineering. Furthermore, the article comprehensively and categorically summarizes some novel bioceramics based AM techniques for the restoration of bones. At prior stages of this article, different ceramics processing AM techniques have been categorized, subsequently, processing of frequently used materials for bone implants and complexities associated with these materials have been elaborated. At the end, some novel applications of bioceramics in orthopedic implants and some future directions are also highlighted to explore it further. This review article will help the new researchers to understand the basic mechanism and current challenges in neophyte techniques and the applications of bioceramics in the orthopedic prosthesis.


MRS Bulletin ◽  
2015 ◽  
Vol 40 (2) ◽  
pp. 137-144 ◽  
Author(s):  
M. Regis ◽  
E. Marin ◽  
L. Fedrizzi ◽  
M. Pressacco

Abstract


Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 1004 ◽  
Author(s):  
Bai ◽  
Gong ◽  
Chen ◽  
Sun ◽  
Zhang ◽  
...  

Metals have been used for orthopedic implants for a long time due to their excellent mechanical properties. With the rapid development of additive manufacturing (AM) technology, studying customized implants with complex microstructures for patients has become a trend of various bone defect repair. A superior customized implant should have good biocompatibility and mechanical properties matching the defect bone. To meet the performance requirements of implants, this paper introduces the biomedical metallic materials currently applied to orthopedic implants from the design to manufacture, elaborates the structure design and surface modification of the orthopedic implant. By selecting the appropriate implant material and processing method, optimizing the implant structure and modifying the surface can ensure the performance requirements of the implant. Finally, this paper discusses the future development trend of the orthopedic implant.


2018 ◽  
Vol 770 ◽  
pp. 9-17 ◽  
Author(s):  
Eugene Ivanov ◽  
Eduardo del Rio ◽  
Igor Kapchemnko ◽  
Maija Nyström ◽  
Juha Kotila

The use and application of alloys as biomedical alloys have increased over the past few years owing to their excellent biocompatibility, corrosion resistance, high mechanical and fatigue resistance, low density, adequate wear resistance, and low elastic modulus. Orthopedic implant materials are exposed to high mechanical loading. Conventional materials based on Ti-6Al-4V, stainless steel or cobalt-chromium alloys demonstrate good mechanical strength, but also some toxicological concerns due to release of toxic elements which may result in inflammatory reactions. Metal alloys based on titanium, zirconium, tantalum and niobium represent higher biocompatibility with appropriate mechanical properties for avoiding stress-shielding and consecutive implant loosening. Application of specifically designed spherical β-titanium alloy powders in additive manufacturing, such as selective laser melting (SLM) or electron beam melting (EBM); enable the production of components with a high degree in freedom of design. Accordingly, SLM or EBM of Ti/Nb (/Ta) alloys offer the possibility to fabricate patient-specific orthopedic implants. The present paper describes development of β-titanium alloys powders designed for application in additive manufacturing technologies. TiNbZrTa (TNZT)-based 3D structures were successfully manufactured and mechanically tested.


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