Mihaela Vlasea

Effect of glycerol concentrations on the mechanical properties of additive manufactured porous calcium polyphosphate structures for bone substitute applications

This article addresses the effects of glycerol (GLY) concentrations on the mechanical properties of calcium polyphosphate (CPP) bone substitute structures manufactured using binder jetting additive manufacturing. To achieve this goal, nine types of water-based binder solutions were prepared with 10, 12.5, and 15 wt % GLY liquid-binding agent, mixed, respectively, with 0, 0.75, and 1.5 wt % ethylene glycol diacetate (EGD) flow enhancer. The print quality of each of the solutions was established quantitatively using an image processing algorithm. The print quality analysis narrowed down the solutions to three batches containing 1.5 wt % EGD and variable amount of GLY. These solutions were used to manufacture porous CPP bone substitute samples, which were characterized physically to determine shrinkage, porosity, microstructure, and compression strength. The 12.5 wt % GLY, 1.5 wt % EGD solution resulted in the highest mechanical strength after sintering (34.6 ± 5.8 MPa), illustrating similar mechanical properties when compared to previous studies (33.9 ± 6.3 MPa) of additively manufactured CPP bone substitutes using a commercially available binder.

Additive Manufacturing for Bone Load Bearing Applications

Current trends in regenerative medicine incorporate additive manufacturing methodologies into producing bone substitute implants from a variety of materials. This chapter provides an overview of compositional, structural, and mechanical requirements for designing bone substitutes, with a focus on load bearing applications for which a heterogeneous porous structure is needed, with varying physical and mechanical characteristics, and complex three-dimensional shape. A review of metallic, bioceramic, and composite materials used for bone substitutes and the corresponding additive manufacturing methodologies is provided, outlining the popularity, benefits, limitations, and opportunities associated with the materials and methodologies.

On the Bio-Mechanical Properties of a Dual-Porous Osteochondral Scaffold

This work is concerned with the finite element modeling of a dual-porous scaffold including both fine and coarse pores. The layer with coarse pores is suitable for bone in vivo ingrowth and the finer pore layer is appropriate for in vitro cartilage culturing. Such scaffolds can be extensively used for repairing of osteochondral defects. The bio-mechanical properties of the proposed scaffold, including apparent stiffness and strain-based capability of the cell ingrowth, are identified using a 3D Finite Element Model. Moreover, to study the effect of the second layer on the strength of the whole scaffold, the stiffness of the dual and single-porous scaffolds was compared. The result of this study shows that the stiffness decreases by adding the second layer to a single-porous scaffold. Additionally, principal strain histograms of the single and the dual-porous scaffolds are compared to assess the effect of added layer on the capability for cell ingrowth stimulation of the whole structure. According to the results, the dual-porous scaffold provides more homogeneous distribution but a smaller amount of micro-strains which may cause different cell-growth behavior.Copyright

Data related to the experimental design for powder bed binder jetting additive manufacturing of silicone

The data included in this article provides additional supporting information on our recent publication (Liravi et al., 2018 [1]) on a novel hybrid additive manufacturing (AM) method for fabrication of three-dimensional (3D) structures from silicone powder. A design of experiments (DoE) study has been carried out to optimize the geometrical fidelity of AM-made parts. This manuscript includes the details of a multi-level factorial DOE and the response optimization results. The variation in the temperature of powder-bed when exposed to heat is plotted as well. Furthermore, the effect of blending ratio of two parts of silicone binder on its curing speed was investigated by conducting DSC tests on a silicone binder with 100:2 precursor to curing agent ratio. The hardness of parts fabricated with non-optimum printing conditions are included and compared.

Data related to the sinter structure analysis of titanium structures fabricated via binder jetting additive manufacturing

The adoption of metal binder jetting additive manufacturing (AM) for functional parts relies on a deep understanding between the materials, the design aspects, the additive manufacturing process and sintering. This work focuses on the relationship between sintering theory and process outcomes. The data included in this article provides additional supporting information on the authors’ recent publication (Wheat et al., 2018 [1]) on the sinter structure analysis of commercially pure titanium parts manufactured using powder bed binder jetting additive manufacturing. For this work, commercially pure titanium was deployed to study the effect of powder size distributions on green and sintered part qualities (bulk density, relative density, particle size, pore size, sinter neck size). This manuscript includes the overall computed tomography visualization methods and results for the green and sintered samples using uni- and bi-modal powders. Moreover, the effective particle and pore size for the different batches of powder are presented.