Analysis of Microstructure Evolution and Mechanical Properties during Compression of Open-Cell Ni-Foams with Hollow Struts Using Micro-CT and FEM

Based on electron backscatter diffraction (EBSD), hollow structures of Ni foam struts fabricated by electroplating on a chemically removable template were observed. Three-dimensional (3D) pore structures of Ni foams were also obtained using X-ray computed tomography (CT), and microstructural features such as porosity, pore size and strut thickness were statistically quantified. Evolution of microstructure and mechanical properties during ex situ compression of open-cell Ni-foams was investigated based on X-ray CT, and experimental results were compared with predictions by the finite element method (FEM). 3D microstructures obtained by X-ray CT revealed that the stress drop started with the buckling of struts at the center of the Ni-foams. The flow stress increased after the buckling of the struts spreads to most of the regions. For effective simulation of the compressive deformation and determination of the microstructural evolution, small domains of interest were selected from the entire set of observed 3D microstructures based on X-ray CT, and struts of Ni foams with a hollow structure were simplified with relevant thin-solid struts. Numerical 3D modeling comprehensively disclosed that compression caused the transverse buckling of the struts, with the bending and buckling of struts thus reducing the stress. Thickness variation of the struts causes a change in the porosity of Ni-foams without a change in pore shape or connectivity. The overall range of strut thickness was from 59 to 133 μm, and the range of porosity values was from 80% to 93.7%. A stress drop was predicted with a decrease in the strut thickness or an increase in the porosity, as measured experimentally. It was also found that the stress drop contributed to an increase in the calculated energy absorption efficiency.

Numerical study of the effect of geometric parameters on compressive mechanical properties of metallic lattice cylinders

In the current research, the numerical simulations were done on 15 cylindrical lattice specimens under compressive stress at a constant strain rate using Abaqus software. The lattice cylinders have different strut thicknesses of 3, 4, and 5 mm, and with the fillets in the radiuses of 0.3, 0.6, 0.9, and 1.2 mm, respectively. The mechanical properties of the AlSi11Cu2 (Fe) aluminum alloy were used. The Mises stress distribution was evaluated to determine the effect of fillet radius on the lattice structure for the strut thickness of 3 mm. Also, the effective strain distribution of the lattice structure was investigated after different stages of deformation. After comparing the simulation results, it was shown that by applying fillets with a radius of 0.3 mm in lattice cylinders, the maximum energy absorption and maximum force can be achieved at the ultimate tensile strength (UTS) point. Also, the optimal strain can be obtained at the UTS point.

Stent strut streamlining and thickness reduction promote endothelialization

Stent thrombosis (ST) carries a high risk of myocardial infarction and death. Lack of endothelial coverage is an important prognostic indicator of ST after stenting. While stent strut thickness is a critical factor in ST, a mechanistic understanding of its effect is limited and the role of haemodynamics is unclear. Endothelialization was tested using a wound-healing assay and five different stent strut models ranging in height between 50 and 150 µm for circular arc (CA) and rectangular (RT) geometries and a control without struts. Under static conditions, all stent strut surfaces were completely endothelialized. Reversing pulsatile disturbed flow caused full endothelialization, except for the stent strut surfaces of the 100 and 150 µm RT geometries, while fully antegrade pulsatile undisturbed flow with a higher mean wall shear stress caused only the control and the 50 µm CA geometries to be fully endothelialized. Modest streamlining and decrease in height of the stent struts improved endothelial coverage of the peri-strut and stent strut surfaces in a haemodynamics dependent manner. This study highlights the impact of the stent strut height (thickness) and geometry (shape) on the local haemodynamics, modulating reendothelialization after stenting, an important factor in reducing the risk of stent thrombosis.

Mesoscale Lattice Structure Design and Simulation with the Support of a Property Database

The lattice structure is a type of cellular materials [1] that has truss-like structures with interconnected struts and nodes in a three-dimensional (3D) space. Compared to other cellular materials such as random foams and honeycombs, the lattice structures exhibit better mechanical performance [2]. Some examples of lattice structures are shown in Figure 8.1. The first one is a randomized lattice structure. Due to the disordered lattice cells, the properties of this type of lattice structures are stochastic and difficult to control. But it can be used as implants in orthopedic surgeries. The second and the third are lattice structures with periodic unit cells. The difference is that the strut thickness of the second one is uniform, which is called homogeneous lattice structures. However, the third one has non-uniform strut thickness for specific loading conditions, which is called heterogeneous lattice structures. By properly adjusting the material in vital parts of the lattice structure, the heterogeneous periodic lattice structure can have a better mechanical performance than the homogeneous one with the same weight. Plenty of design and optimization methods [3-5] have been proposed for lattice structures to pursue better performance in different engineering applications. For example, the lattice structure is applied to achieve lightweight [3, 4], energy absorption [6], and thermal management [7]. Due to the complexity of the geometry, the fabrication of lattice structures had been the most critical issue. However, with the development of Additive Manufacturing (AM) processes, the difficulty in the fabrication was largely relieved.

PDLLA-Zn-nitrided Fe bioresorbable scaffold with 53-μm-thick metallic struts and tunable multistage biodegradation function

Balancing the biodegradability and mechanical integrity of a bioresorbable scaffold (BRS) with time after implantation to match the remodeling of the scaffolded blood vessel is important, but a key challenge in doing so remains. This study presents a novel intercalated structure of a metallic BRS by introducing a nanoscale Zn sacrificial layer between the nitrided Fe platform and the sirolimus-carrying poly(d,l-lactide) drug coating. The PDLLA-Zn-FeN BRS shows a multistage biodegradation behavior, maintaining mechanical integrity at the initial stage and exhibiting accelerated biodegradation at the subsequent stage in both rabbit abdominal aortas and human coronary arteries, where complete biodegradation was observed about 2 years after implantation. The presence of the nanoscale Zn sacrificial layer with an adjustable thickness also contributes to the tunable biodegradation of BRS and allows the reduction of the metallic strut thickness to 53 μm, with radial strength as strong as that of the current permanent drug-eluting stents.

Manufacturing and Characterization of 3D Miniature Polymer Lattice Structures Using Fused Filament Fabrication

The potential of additive manufacturing to produce architected lattice structures is remarkable, but restrictions imposed by manufacturing processes lead to practical limits on the form and dimension of structures that can be produced. In the present work, the capabilities of fused filament fabrication (FFF) to produce miniature lattices were explored, as they represent an inexpensive option for the production of polymer custom-made lattice structures. First, fused filament fabrication design guidelines were tested to assess their validity for miniature unit cells and lattice structures. The predictions were contrasted with the results of printing tests, showing some discrepancies between expected outcomes and resulting printed structures. It was possible to print functional 3D miniature open cell polymer lattice structures without support, even when some FFF guidelines were infringed, i.e., recommended minimum strut thickness and maximum overhang angle. Hence, a broad range of lattice structures with complex topologies are possible, beyond the cubic-type cell arrangements. Nevertheless, there are hard limits in 3D printing of miniature lattice structures. Strut thickness, length and orientation were identified as critical parameters in miniature lattice structures. Printed lattices that did not fully comply with FFF guidelines were capable of bearing compressive loads, even if surface quality and accuracy issues could not be fully resolved. Nevertheless, 3D printed FFF lattice structures could represent an improvement compared to other additive manufacturing processes, as they offer good control of cell geometry, and does not require additional post-processing.

Abstract 12894: Suppressed Local Coagulative Response After Newer-generation Ultrathin Strut SES Implantation Compared to Older-generation SES Implantation

Background: We have previously demonstrated local persistent hypercoagulation after durable polymer (DP)-sirolimus-eluting stent (SES) implantation by measuring plasma prothrombin fragment 1+2 (F1+2) levels. The aim of this study is to evaluate local coagulative response after newer-generation ultrathin strut SES implantation. Method: Forty-five patients who were treated about 6-12 months earlier with coronary stenting, with no evidence of restenosis, were studied [DP-SES (Cypher): 26pts, biodegradable polymer (BP)-SES (older BP-SES, Ultimaster): 12pts and ultrathin strut BP-SES (newer BP-SES, Orsiro): 7pts]. We measured plasma levels of F1+2 sampled in coronary sinus (CS) and sinus of Valsalva (V). The transcardiac gradient (Δ) was defined as CS level minus V level. Results: No significant difference was observed in the percent diameter stenosis among DP-SES, older BP-SES, and newer BP-SES groups (10.1 ± 16.5 vs 13.1 ± 12.9 vs 12.1 ± 11.9 %). The ΔF1+2 was significantly lower in the BP-SES groups than in the DP-SES group (8.9 ± 10.1 vs 23.4 ± 21.1 pmol/l, p<0.05). The ΔF1+2 was lower in the newer BP-SES group than in the older BP-SES group, however, significant difference was not observed (7.0 ± 7.0 vs 9.7 ± 12.3 pmol/l). Conclusion: Suppressed local coagulative response after newer-generation ultrathin strut SES implantation was observed. These findings might indicate that lower strut thickness is more important factor than faster polymer resorption in the newer-generation DES era.

Post-Processing Treatment Impact on Mechanical Properties of SLM Deposited Ti-6Al-4 V Porous Structure for Biomedical Application

Additive manufacturing technologies allow producing a regular three-dimensional mesh of interconnected struts that form an open-cell porous structure. Regular porous structures have been used in the orthopedic industry due to outstanding bone anchoring. The aim of the study was to determine how the postprocessing influences the mechanical properties of porous structures made of titanium alloy CL 41TI ELI. The effect of hot isostatic pressing (HIP) as a method of increasing microstructural integrity was investigated here. The influence of surface etching (SE) technique, which was applied to the porous structure for cleaning unmelted titanium powder particles on the surface of connectors from the inner surfaces of a porous structure, was examined in this study. Mechanical properties were investigated by means of compression tests. The results point out that HIP has a minor effect on the mechanical behavior of considered porous structures. The SE is an effective method to clean the surface of a porous structure, which is very important in the case of biomedical applications when loose powder can cause serious health problems. Another effect of the SE is also the strut thickness reduction. Reducing strut thickness of a porous structure with the surface etching decreases its stiffness to the same extent as predicted by the relative density theoretical model but did not result in structural damage.