Mathew Speirs

Surface Roughness and Morphology Customization of Additive Manufactured Open Porous Ti6Al4V Structures

Additive manufacturing (AM) is a production method that enables the building of porous structures with a controlled geometry. However, there is a limited control over the final surface of the product. Hence, complementary surface engineering strategies are needed. In this work, design of experiments (DoE) was used to customize post AM surface treatment for 3D selective laser melted Ti6Al4V open porous structures for bone tissue engineering. A two-level three-factor full factorial design was employed to assess the individual and interactive effects of the surface treatment duration and the concentration of the chemical etching solution on the final surface roughness and beam thickness of the treated porous structures. It was observed that the concentration of the surface treatment solution was the most important factor influencing roughness reduction. The designed beam thickness decreased the effectiveness of the surface treatment. In this case study, the optimized processing conditions for AM production and the post-AM surface treatment were defined based on the DoE output and were validated experimentally. This allowed the production of customized 3D porous structures with controlled surface roughness and overall morphological properties, which can assist in more controlled evaluation of the effect of surface roughness on various functional properties.

Fatigue behaviour of NiTi shape memory alloy scaffolds produced by SLM, a unit cell design comparison

Selective laser melting (SLM) is an additive manufacturing technique able to produce complex functional parts via successively melting layers of metal powder. This process grants the freedom to design highly complex scaffold components to allow bone ingrowth and aid mechanical anchorage. This paper investigates the compression fatigue behaviour of three different unit cells (octahedron, cellular gyroid and sheet gyroid) of SLM nitinol scaffolds. It was found that triply periodic minimal surfaces display superior static mechanical properties in comparison to conventional octahedron beam lattice structures at identical volume fractions. Fatigue resistance was also found to be highly geometry dependent due to the effects of AM processing techniques on the surface topography and notch sensitivity. Geometries minimising nodal points and the staircase effect displayed the greatest fatigue resistance when normalized to yield strength. Furthermore oxygen analysis showed a large oxygen uptake during SLM processing which must be altered to meet ASTM medical grade standards and may significantly reduce fatigue life. These achieved fatigue properties indicate that NiTi scaffolds produced via SLM can provide sufficient mechanical support over an implants lifetime within stress range values experienced in real life.

Additively Manufactured and Surface Biofunctionalized Porous Nitinol

Enhanced bone tissue regeneration and improved osseointegration are among the most important goals in design of multifunctional orthopedic biomaterials. In this study, we used additive manufacturing (selective laser melting) to develop multifunctional porous nitinol that combines superelasticity with a rationally designed microarchitecture and biofunctionalized surface. The rational design based on triply periodic minimal surfaces aimed to properly adjust the pore size, increase the surface area (thereby amplifying the effects of surface biofunctionalization), and resemble the curvature characteristics of trabecular bone. The surface of additively manufactured (AM) porous nitinol was biofunctionalized using polydopamine-immobilized rhBMP2 for better control of the release kinetics. The actual morphological properties of porous nitinol measured by microcomputed tomography (e.g., open/close porosity, and surface area) closely matched the design values. The superelasticity originated from the austenite phase formed in the nitinol porous structure at room temperature. Polydopamine and rhBMP2 signature peaks were confirmed by X-ray photoelectron spectroscopy and Fourier transform infrared spectroscopy tests. The release of rhBMP2 continued until 28 days. The early time and long-term release profiles were found to be adjustable independent of each other. In vitro cell culture showed improved cell attachment, cell proliferation, cell morphology (spreading, spindle-like shape), and cell coverage as well as elevated levels of ALP activity and increased calcium content for biofunctionalized surfaces as compared to as-manufactured specimens. The demonstrated functionalities of porous nitinol could be used as a basis for deployable orthopedic implants with rationally designed microarchitectures that maximize bone tissue regeneration performance by release of biomolecules with adjustable and well-controlled release profiles.

Microstructural Analysis and Mechanical Evaluation of Ti‐45Nb Produced by Selective Laser Melting towards Biomedical Applications

Selective laser melting (SLM) is an additive manufacturing (AM) technique to produce complex parts. However, Ti-45Nb (with a low stiffness as well as an excellent biocompatibility and corrosion resistance) is not yet developed by this process towards biomedical applications. Therefore, this work is to analyze SLM Ti-45Nb with an engineered content of porosity. It is shown that the combination of porosity and the material property can lead to an elastic modulus within the range observed for a bone. The matrix contains only a β-phase after laser rapid solidification. The β-phase is composed of larger laser solidified grains embedding numerous submicron/ultrafine subgrains. The ultrafine subgrains enable a high ductility in conjunction with a satisfactory compressive strength (despite the presence of porosity). The SLM full melting, assessed by the shear strength evaluations, also contributes to the satisfactory mechanical strength. The findings are very promising to benefit biomedical implants for load-bearing applications.