Changjun Han

Porous niobium coatings fabricated with selective laser melting on titanium substrates: Preparation, characterization, and cell behavior

Nb, an expensive and refractory element with good wear resistance and biocompatibility, is gaining more attention as a new metallic biomaterial. However, the high price of the raw material, as well as the high manufacturing costs because of Nbs strong oxygen affinity and high melting point have limited the widespread use of Nb and its compounds. To overcome these disadvantages, porous Nb coatings of various thicknesses were fabricated on Ti substrate via selective laser melting (SLM), which is a 3D printing technique that uses computer-controlled high-power laser to melt the metal. The morphology and microstructure of the porous Nb coatings, which had pores ranging from 15 to 50 μm in size, were characterized with scanning electron microscopy (SEM). The average hardness of the coating, which was measured with the linear intercept method, was 392±37 HV. In vitro tests of the porous Nb coating which was monitored with SEM, immunofluorescence, and CCK-8 counts of cells, exhibited excellent cell morphology, attachment, and growth. The simulated body fluid test also proved the bioactivity of the Nb coating. Therefore, these new porous Nb coatings could potentially be used for enhanced early biological fixation to bone tissue. In addition, this study has shown that SLM technique could be used to fabricate coatings with individually tailored shapes and/or porosities from group IVB and VB biomedical metals and their alloys on stainless steel, Co-Cr, and other traditional biomedical materials without wasting raw materials.

Continuous functionally graded porous titanium scaffolds manufactured by selective laser melting for bone implants

A significant requirement for a bone implant is to replicate the functional gradient across the bone to mimic the localization change in stiffness. In this work, continuous functionally graded porous scaffolds (FGPSs) based on the Schwartz diamond unit cell with a wide range of graded volume fraction were manufactured by selective laser melting (SLM). The micro-topology, strut dimension characterization and effect of graded volume fraction on the mechanical properties of SLM-processed FGPSs were systematically investigated. The micro-topology observations indicate that diamond FGPSs with a wide range of graded volume fraction from 7.97% to 19.99% were fabricated without any defects, showing a good geometric reproduction of the original designs. The dimensional characterization demonstrates the capability of SLM in manufacturing titanium diamond FGPSs with the strut size of 483-905µm. The elastic modulus and yield strength of the titanium diamond FGPSs can be tailored in the range of 0.28-0.59GPa and 3.79-17.75MPa respectively by adjusting the graded volume fraction, which are comparable to those of the cancellous bone. The mathematical relationship between the graded porosity and compression properties of a FGPS was revealed. Furthermore, two equations based on the Gibson and Ashby model have been established to predict the modulus and yield strength of SLM-processed diamond FGPSs. Compared to homogeneous diamond porous scaffolds, FGPSs provide a wide range of mutative pore size and porosity, which are potential to be tailored to optimize the pore space for bone tissue growth. The findings provide a basis of new methodologies to design and manufacture superior graded scaffolds for bone implant applications.

Microstructure and property evolutions of titanium/nano-hydroxyapatite composites in-situ prepared by selective laser melting

Titanium (Ti)-hydroxyapatite (HA) composites have the potential for orthopedic applications due to their favorable mechanical properties, excellent biocompatibility and bioactivity. In this work, the pure Ti and nano-scale HA (Ti-nHA) composites were in-situ prepared by selective laser melting (SLM) for the first time. The phase, microstructure, surface characteristic and mechanical properties of the SLM-processed Ti-nHA composites were studied by X-ray diffraction, transmission electron microscope, atomic force microscope and tensile tests, respectively. Results show that SLM is a suitable method for fabricating the Ti-nHA composites with refined microstructure, low modulus and high strength. A novel microstructure evolution can be illustrated as: Relatively long lath-shaped grains of pure Ti evolved into short acicular-shaped and quasi-continuous circle-shaped grains with the varying contents of nHA. The elastic modulus of the Ti-nHA composites is 3.7% higher than that of pure Ti due to the effect of grain refinement. With the addition of 2% nHA, the ultimate tensile strength significantly reduces to 289MPa but still meets the application requirement of bone implants. The Ti-nHA composites exhibit a remarkable improvement of microhardness from 336.2 to 600.8 HV and nanohardness from 5.6 to 8.3GPa, compared to those of pure Ti. Moreover, the microstructure and property evolution mechanisms of the composites with the addition of HA were discussed and analyzed. It provides some new knowledge to the design and fabrication of biomedical material composites for bone implant applications.

Effects of the unit cell topology on the compression properties of porous Co-Cr scaffolds fabricated via selective laser melting

Purpose Selective laser melting (SLM) is an additive manufacturing process suitable for fabricating metal porous scaffolds. The unit cell topology is a significant factor that determines the mechanical property of porous scaffolds. Therefore, the purpose of this paper is to evaluate the effects of unit cell topology on the compression properties of porous Cobalt–chromium (Co-Cr) scaffolds fabricated by SLM using finite element (FE) and experimental measurement methods. Design/methodology/approach The Co-Cr alloy porous scaffolds constructed in four different topologies, i.e. cubic close packed (CCP), face-centered cubic (FCC), body-centered cubic (BCC) and spherical hollow cubic (SHC), were designed and fabricated via SLM process. FE simulations and compression tests were performed to evaluate the effects of unit cell topology on the compression properties of SLM-processed porous scaffolds. Findings The Mises stress predicted by FE simulations showed that different unit cell topologies resulted in distinct stress distributions on the bearing struts of scaffolds, whereas the unit cell size directly determined the stress value. Comparisons on the stress results for four topologies showed that the FCC unit cell has the minimum stress concentration due to its inclined bearing struts and horizontal arms. Simulations and experiments both indicated that the compression modulus and strengths of FCC, BCC, SHC, CCP scaffolds with the same cell size presented in a descending order. These distinct compression behaviors were correlated with the corresponding mechanics response on bearing struts. Two failure mechanisms, cracking and collapse, were found through the results of compression tests, and the influence of topological designs on the failure was analyzed and discussed. Finally, the cell initial response of the SLM-processed Co-Cr scaffold was tested through the in vitro cell culture experiment. Originality/value A focus and concern on the compression properties of SLM-processed porous scaffolds was presented from a new perspective of unit cell topology. It provides some new knowledge to the structure optimization of porous scaffolds for load-bearing bone implants.

Electrophoretic deposition of chitosan/gelatin coatings with controlled porous surface topography to enhance initial osteoblast adhesive responses

Electrophoretically deposited (EPD) coatings have often been employed recently for the addition of different new chemical compositions to classic chitosan coatings to improve the biocompatibility and therapeutic potential of coated implants. However, little attention has been paid to enhance the cell response to EPD coatings via integrating the effects of chemical components and surface topography. Here, we fabricated EPD chitosan/gelatin (CS/G) coatings with controlled porous surface topography by controlling bubble generation in the EPD process via changing the gelatin content in solution from 0, 0.01, 0.1, and 1 to 10 mg ml-1. The pure chitosan coating surface was characterized by homogeneous large pores of 500 μm. After 0.01 mg ml-1 gelatin was added, 180 μm small pores appeared on the walls of large pores. As the gelatin content increased to 0.1 mg ml-1, a number of small pores increased noticeably. When the gelatin content reached 1 mg ml-1, large pores disappeared, and the coating displayed homogeneous small pores. 10 mg ml-1 gelatin concentration led to coatings consisting of small pores with not integral and continuous structures. The initial osteoblastic responses, including cell adherence progress, spreading area, proliferation rate, and focal adhesion-related gene expression, gradually improved from 0 to 0.01, 0.1, and 1 mg ml-1 gelatin content, but decreased from 1 to 10 mg ml-1. All these results indicated that the initial cell responses to coatings reached a peak when it was 1 mg ml-1 gelatin and they had homogeneous small pores, which might contribute to the synergistic effects of the porous surface structure and components. This work would be beneficial for expanding the potential application of EPD coatings.

Study on the selective laser sintering of a low-isotacticity polypropylene powder

Purpose Semi-crystalline polymers such as polyamide-12 can be used for selective laser sintering (SLS) to make near-fully dense plastic parts. At present, however, the types of semi-crystalline polymers suitable for SLS are critically limited. Therefore, the purpose of this paper is to investigate the processibility of a new kind of semi-crystalline polypropylene (PP) with low isotacticity for SLS process. Design/methodology/approach The SLS processibility of the PP powder, including particle size and shape, sintering window, degree of crystallinity and degradation temperature, was evaluated. Effects of the applied laser energy density on the surface micromorphology, density, tensile strength and thermal properties of SLS-built PP specimens were studied. Findings The results show that the PP powder has a nearly spherical shape, smooth surfaces, an appropriate average particle size of 63.6 μm, a broad sintering window of 21 oC and low crystalline degree of 30.4 per cent comparable to that of polyamide-12, a high degradation temperature of 381.8°C and low part bed temperature of 105°C, indicating a very good SLS processibility. The density and the tensile strength first increase with increasing laser energy density until they reach the maximum values of 0.831 g/cm3 and 19.9 MPa, respectively, at the laser energy density of 0.0458 J/mm2, and then decrease when the applied laser energy density continue to increase owing to the degradation of PP powders. The complex PP components have been manufactured by SLS using the optimum parameters, which are strong enough to be directly used as functional parts. Originality/value This paper provides a new knowledge for this field that low-isotacticity PPs exhibit good SLS processibility, therefore increasing material types and broadening the application of SLS technology.

Effect of pore geometry on the fatigue properties and cell affinity of porous titanium scaffolds fabricated by selective laser melting

Porous titanium scaffolds with different unit cell type (tetrahedron and octahedron) and pore size (500 µm and 1000 µm) were fabricated by selective laser melting (SLM), and the effects of unit cell type and pore size on their fatigue properties and cell affinity were studied. The fatigue properties were performed by static and dynamic mechanical testing, while the cell affinity was evaluated in vitro with mouse osteoblast cells. It was found that octahedron scaffolds exhibited superior static mechanical properties, longer fatigue lives and higher fatigue strength in comparison to those of tetrahedron ones. As expected, scaffolds with 1000 µm pore resulted in lower compressive properties and shorter fatigue lives compared to those with 500 µm pore. The differences were analyzed based on the unit cell structure, porosity, and manufacturing imperfections. Scanning electron microscopy (SEM) and immunofluorescence showed that cells spread better on octahedron scaffolds than those on tetrahedron ones. Meanwhile, the scaffolds with 1000 µm pore were more suitable for cell attachment and growth within the same unit cell owing to higher porosity. The comparison of different pore geometry on the mechanical and biological property provided further insight into designing an optimal porous scaffold.

Electrophoretic Deposition of Gentamicin-Loaded Silk Fibroin Coatings on 3D-Printed Porous Cobalt–Chromium–Molybdenum Bone Substitutes to Prevent Orthopedic Implant Infections

In addition to customizing shapes of metal bone substitutes for patients, the 3D printing technique can reduce the modulus of the substitutes through the design and manufacture of interconnected porous structures, achieving the modulus match between substitute and surrounding bone to improve implant longevity. However, the porous bone substitutes take more risks of postoperative infection due to its much larger surface area compared with the traditional casting solid bone substitute. Here, we prepared of gentamicin-loaded silk fibroin coatings on 3D-printed porous cobalt-chromium-molybdenum (CoCrMo) bone substitutes via electrophoretic deposition technique. Through optimization, relatively intact, continuous, homogeneous, and conformal coatings with a thickness of 2.30 ± 0.58 μm were deposited around the struts with few pore blocked. The porous metal structures exhibited no loss in mechanical properties after the anode galvanic corrosion in EPD process. The initial osteoblastic response on coatings was better than that on metal surface, including cell spreading, proliferation and cytotoxicity. Antibacterial efficacy experiments showed that the coatings had an antibacterial effect on both adherent and planktonic bacteria within 1 week. These results suggested that the beneficial properties of anode electrophoretic deposited silk fibroin coatings could be exploited to improve the biological functionality of porous structures made of medical metals.