Abdul Manaf Abdullah

Preparation and characterization of a newly developed polyamide composite utilising an affordable 3D printer

In this work, the potential of polyamide composite prepared by a 3D printer was evaluated. Polyamide 12 was compounded with 5 wt% hydroxyapatite and 15 wt% zirconium oxide fillers via a twin screw extruder. The compound was then pelletized prior to the preparation of the filament by a desktop filament extruder. The filament was finally applied to a 3D printer to prepare the printed tensile samples. Pure polyamide 12 and commercial polyamide filament, Taulman 618, were also printed and tested for control. Melt flow and thermal analysis were carried out to estimate the processing conditions. Tensile test was also conducted to evaluate the strength and modulus. The new polyamide composite was successfully prepared and tested. The strength of polyamide composite was comparable to Taulman 618. The modulus of the composite was improved due to the incorporation of fillers. The morphology of the printed composite was porous, which could provide pros and cons to biological and mechanical properties, respectively. Polyamide composite presented a promising polymer material for a 3D printer and may be applied for biomaterial application.

Mechanical and cytotoxicity properties of hybrid ceramics filled polyamide 12 filament feedstock for craniofacial bone reconstruction via fused deposition modelling

OBJECTIVE To compare the mechanical and biological properties of newly developed hybrid ceramics filled and unfilled polyamide 12 (PA 12) for craniofacial reconstruction via a fused deposition modelling (FDM) framework. METHODS 15wt% of zirconia (ZrO2) as well as 30, 35, and 40wt% of beta-tricalcium phosphate (β-TCP) were compounded with PA 12, followed by the fabrication of filament feedstocks using a single screw extruder. The fabricated filament feedstocks were used to print the impact specimens. The melt flow rate, tensile properties of fabricated filament feedstocks, and 3D printed impact properties of the specimens were assessed using melt flow indexer, universal testing machine, and Izod pendulum tester, respectively. The microstructure of selected filament feedstocks and broken impact specimens were analysed using a field emission scanning electron microscope and universal testing machine. Human periodontal ligament fibroblast cells (HPdLF) were used to evaluate the cytotoxicity of the materials by (3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazoliumbromid) (MTT) assay. RESULTS Hybrid ceramics filled PA 12 indicated sufficient flowability for FDM 3D printing. The tensile strength of hybrid ceramics filled PA 12 filament feedstocks slightly reduced as compared to unfilled PA 12. However, the tensile modulus and impact strength of hybrid ceramics filled PA 12 increased by 8%-31% and 98%-181%, respectively. A significant increase was also detected in the cell viability of the developed composites at concentrations of 12.5, 25, 50 and 100mg/ml. SIGNIFICANCE The newly developed hybrid ceramics filled PA 12 filament feedstock with improved properties is suitable for an FDM-based 3D printer, which enables the creation of patient-specific craniofacial implant at a lower cost to serve low-income patients.

Effect of zinc oxide on flexural and physical properties of PMMA composites

Polymethylmethacrylate (PMMA) is the most widely accepted material in maxillofacial implants due to its superior advantages. The material used for craniofacial implant should have good mechanical and antibacterial properties to withstand forces and eliminate infection. A study was conducted to prepare PMMA incorporated with β-tricalcium phosphate (β -TCP) filler and zinc oxide as an antibacterial agent at different compositions and investigate the flexural properties of the produced PMMA/β- TCP/ZnOcomposites. Pure PMMA as control,15 % β –TCP filled, 15% β –TCPwith 2.5% ZnO filled as well as15% β -TCPwith5% ZnOfilled PMMA were prepared. PMMA were mixed together with β -TCP and zinc oxide manually according to the percentages specified until it has reached the homogeneous state. Flexural specimens were prepared by casting the paste in silicone mould which has been fabricated using 3D printed flexural template. The number of samples was n=7 for each composition. Statistical analysis of One Way ANOVA was empl...

Surface topography study of prepared 3D printed moulds via 3D printer for silicone elastomer based nasal prosthesis

Conventional prosthesis fabrication is highly depends on the hand creativity of laboratory technologist. The development in 3D printing technology offers a great help in fabricating affordable and fast yet esthetically acceptable prostheses. This study was conducted to discover the potential of 3D printed moulds for indirect silicone elastomer based nasal prosthesis fabrication. Moulds were designed using computer aided design (CAD) software (Solidworks, USA) and converted into the standard tessellation language (STL) file. Three moulds with layer thickness of 0.1, 0.2 and 0.3mm were printed utilizing polymer filament based 3D printer (Makerbot Replicator 2X, Makerbot, USA). Another one mould was printed utilizing liquid resin based 3D printer (Objet 30 Scholar, Stratasys, USA) as control. The printed moulds were then used to fabricate maxillofacial silicone specimens (n=10)/mould. Surface profilometer (Surfcom Flex, Accretech, Japan), digital microscope (KH77000, Hirox, USA) and scanning electron microsc...

Comparison of mechanical properties for polyamide 12 composite-based biomaterials fabricated by fused filament fabrication and injection molding

The emergence of 3D printing technology known as fused filament fabrication (FFF) has offered the possibility of producing an anatomically accurate, patient specific implant with more affordable prices. The only weakness of this technology is related to incompatibility and lack of properties of current material to be applied in biomedical. Therefore, this study aims to develop a new, polymer composite-based biomaterial that exhibits a high processability using FFF technique, strong enough and shows acceptable biocompatibility, and safe for biomedical use. Polyamide 12 (PA12), which meets all these requirements was incorporated with two bioceramic fillers, zirconia and hydroxyapatite in order to improve the mechanical and bioactivity properties. The obtained mechanical properties were compared with injection-molded specimens and also a commercial biomedical product, HAPEXTM which is composed of hydroxyapatite and polyethylene. The yield strength and modulus of the PA12 composites increased steadily with in...

Design and fabrication of facial prostheses for cancer patient applying computer aided method and manufacturing (CADCAM)

Facial defects are either congenital or caused by trauma or cancer where most of them affect the person appearance. The emotional pressure and low self-esteem are problems commonly related to patient with facial defect. To overcome this problem, silicone prosthesis was designed to cover the defect part. This study describes the techniques in designing and fabrication for facial prosthesis applying computer aided method and manufacturing (CADCAM). The steps of fabricating the facial prosthesis were based on a patient case. The patient was diagnosed for Gorlin Gotz syndrome and came to Hospital Universiti Sains Malaysia (HUSM) for prosthesis. The 3D image of the patient was reconstructed from CT data using MIMICS software. Based on the 3D image, the intercanthal and zygomatic measurements of the patient were compared with available data in the database to find the suitable nose shape. The normal nose shape for the patient was retrieved from the nasal digital library. Mirror imaging technique was used to mir...

Patient-specific reconstruction utilizing computer assisted 3D modelling for partial bone flap defect in hybrid cranioplasty

Autologous cranioplasty using a patient’s original bone flap remain the commonest practice nowadays. However, partial bone flap defect is commonly encountered. Replacing the bone flap with pre-moulded synthetic bone flap is costly and not affordable to many patients. Hence most of the small to medium size defect was topped up with alloplastic material on a free hand basis intra-operatively which often resulted in inaccurate implant approximation with unsatisfactory cosmetic result. This study aims to evaluate implant accuracy and cosmetic outcome of cranioplasty candidates who underwent partial bone flap reconstruction utilising computer assisted 3D modelling. 3D images of the skull were obtained from post-craniectomy axial 1-mm spiral computed tomography (CT) scans and a virtual 3D model was generated using the Materialise Mimics software. The Materialise 3-Matic was then utilised to design a patient-specific implant. Prefabrication of the implant was performed by the 3D Objet printer, and a negative gyp...