Zahra S. Bagheri

Fabrication and characterization of novel biomimetic PLLA/cellulose/hydroxyapatite nanocomposite for bone repair applications

The purpose of this research is to develop and characterize a novel biomimetic nanocomposite that closely mimics the properties of real bone such as morphology, composition and mechanical characteristics. This novel porous nanocomposite is composed of cotton-sourced cellulose microcrystals, hydroxyapatite nanoparticles and poly l-lactide acid. A unique combination of commonly used fabrication procedures has been developed including pre-treatment of particles using a coupling agent. The effect of various weight ratios of the reinforcing agents was evaluated to assess their influence on the chemical, thermal, and mechanical properties of the nanocomposites. The prepared nanocomposites were characterized using Fourier transform infrared spectroscopy, scanning electron microscopy, differential scanning calorimetry and compression testing. Our results indicated the presence of molecular interactions between all components leading to an increase of the crystallinity of the polymer from 50% to 80%. Compression test results revealed that increasing the weight ratio of microcrystalline cellulose/poly l-lactide acid and hydroxyapatite/poly l-lactide acid from 0.1 to 0.5 enhanced the compressive yield stress from 0.127 to 2.2MPa and The Youngs modulus from 6.6 to 38MPa, respectively. It was found that the fabricated nanocomposites are comparable with the trabecular bone from compositional, structural, and mechanical point of view.

Compensation strategy to reduce geometry and mechanics mismatches in porous biomaterials built with Selective Laser Melting.

The accuracy of Additive Manufacturing processes in fabricating porous biomaterials is currently limited by their capacity to render pore morphology that precisely matches its design. In a porous biomaterial, a geometric mismatch can result in pore occlusion and strut thinning, drawbacks that can inherently compromise bone ingrowth and severely impact mechanical performance. This paper focuses on Selective Laser Melting of porous microarchitecture and proposes a compensation scheme that reduces the morphology mismatch between as-designed and as-manufactured geometry, in particular that of the pore. A spider web analog is introduced, built out of Ti-6Al-4V powder via SLM, and morphologically characterized. Results from error analysis of strut thickness are used to generate thickness compensation relations expressed as a function of the angle each strut formed with the build plane. The scheme is applied to fabricate a set of three-dimensional porous biomaterials, which are morphologically and mechanically characterized via micro Computed Tomography, mechanically tested and numerically analyzed. For strut thickness, the results show the largest mismatch (60% from the design) occurring for horizontal members, reduces to 3.1% upon application of the compensation. Similar improvement is observed also for the mechanical properties, a factor that further corroborates the merit of the design-oriented scheme here introduced.

Osteogenesis and cytotoxicity of a new Carbon Fiber/Flax/Epoxy composite material for bone fracture plate applications

This study is part of an ongoing program to develop a new CF/Flax/Epoxy bone fracture plate to be used in orthopedic trauma applications. The purpose was to determine this new plates in-vitro effects on the level of bone formation genes, as well as cell viability in comparison with a medical grade metal (i.e. stainless steel) commonly employed for fabrication of bone plates (positive control). Cytotoxicity and osteogenesis induced by wear debris of the material were assessed using Methyl Tetrazolium (MTT) assay and reverse transcription polymerase chain reaction (RT-PCR) for 3 osteogenesis specific gene markers, including bone morphogenetic proteins (BMP2), runt-related transcription factor 2 (Runx2) and Osterix. Moreover, the Flax/Epoxy and CF/Epoxy composites were examined separately for their wettability properties by water absorption and contact angle (CA) tests using the sessile drop technique. The MTT results for indirect and direct assays indicated that the CF/Flax/Epoxy composite material showed comparable cell viability with no cytotoxicity at all incubation times to that of the metal group (p≥0.05). Osteogenesis test results showed that the expression level of Runx2 marker induced by CF/Flax/Epoxy were significantly higher than those induced by metal after 48 h (p=0.57). Also, the Flax/Epoxy composite revealed a hydrophilic character (CA=68.07°±2.05°) and absorbed more water up to 17.2% compared to CF/Epoxy, which reached 1.25% due to its hydrophobic character (CA=93.22°±1.95°) (p<0.001). Therefore, the new CF/Flax/Epoxy may be a potential candidate for medical applications as a bone fracture plate, as it showed similar cell viability with no negative effect on gene expression levels responsible for bone formation compared to medical grade stainless steel.

Mechanical characterization of structurally porous biomaterials built via additive manufacturing: experiments, predictive models, and design maps for load-bearing bone replacement implants

Porous biomaterials can be additively manufactured with micro-architecture tailored to satisfy the stringent mechano-biological requirements imposed by bone replacement implants. In a previous investigation, we introduced structurally porous biomaterials, featuring strength five times stronger than commercially available porous materials, and confirmed their bone ingrowth capability in an in vivo canine model. While encouraging, the manufactured biomaterials showed geometric mismatches between their internal porous architecture and that of its as-designed counterpart, as well as discrepancies between predicted and tested mechanical properties, issues not fully elucidated. In this work, we propose a systematic approach integrating computed tomography, mechanical testing, and statistical analysis of geometric imperfections to generate statistical based numerical models of high-strength additively manufactured porous biomaterials. The method is used to develop morphology and mechanical maps that illustrate the role played by pore size, porosity, strut thickness, and topology on the relations governing their elastic modulus and compressive yield strength. Overall, there are mismatches between the mechanical properties of ideal-geometry models and as-manufactured porous biomaterials with average errors of 49% and 41% respectively for compressive elastic modulus and yield strength. The proposed methodology gives more accurate predictions for the compressive stiffness and the compressive strength properties with a reduction of the average error to 11% and 7.6%. The implications of the results and the methodology here introduced are discussed in the relevant biomechanical and clinical context, with insight that highlights promises and limitations of additively manufactured porous biomaterials for load-bearing bone replacement implants. STATEMENT OF SIGNIFICANCE In this work, we perform mechanical characterization of load-bearing porous biomaterials for bone replacement over their entire design space. Results capture the shift in geometry and mechanical properties between as-designed and as-manufactured biomaterials induced by additive manufacturing. Characterization of this shift is crucial to ensure appropriate manufacturing of bone replacement implants that enable biological fixation through bone ingrowth as well as mechanical property harmonization with the native bone tissue. In addition, we propose a method to include manufacturing imperfections in the numerical models that can reduce the discrepancy between predicted and tested properties. The results give insight into the use of structurally porous biomaterials for the design and additive fabrication of load-bearing implants for bone replacement.

The Biomechanical Effect of Loading Speed on Metal-on-UHMWPE Contact Mechanics

Ultra high molecular weight polyethylene (UHMWPE) is a material commonly used in total hip and knee joint replacements. Numerous studies have assessed the effect of its viscoelastic properties on phenomena such as creep, stress relaxation, and tensile stress. However, these investigations either use the complex 3D geometries of total hip and knee replacements or UHMWPE test objects on their own. No studies have directly measured the effect of vertical load application speed on the contact mechanics of a metal sphere indenting UHMWPE. To this end, a metal ball was used to apply vertical force to a series of UHMWPE flat plate specimens over a wide range of loading speeds, namely, 1, 20, 40, 60, 80, 100, and 120 mm/min. Pressure sensitive Fujifilm was placed at the interface to measure contact area. Experimental results showed that maximum contact force ranged from 3596 to 4520 N and was logarithmically related (R2=0.96) to loading speed. Average contact area ranged from 76.5 to 79.9 mm2 and was linearly related (R2=0.56) to loading speed. Average contact stress ranged from 45.1 to 58.2 MPa and was logarithmically related (R2=0.95) to loading speed. All UHMWPE specimens displayed a circular area of permanent surface damage, which did not disappear with time. This study has practical implications for understanding the contact mechanics of hip and knee replacements for a variety of activities of daily living.

Thermographic Stress Analysis of Whole Bones and Implants

Experimental stress analysis of whole bones, implants, and whole bone–implant constructs is an important approach in orthopaedic biomechanics. High stresses in whole bones and implants may cause mechanical failure, but low stresses in whole bone may cause “stress shielding,” which leads to bone atrophy, bone resorption, and implant loosening. Surface strain gages are the “gold standard” tool for strain (and stress) analysis in this field, but strain gages are not fully reliable near high peak strains, provide only average strain at each location, cannot yield strain maps of the entire surface, are easily physically damaged, can permanently damage the surface during the mounting process, and have physical dimensions that limit where they can be mounted. Thermographic stress analysis (TSA) is an alternative, easy-to-use, point-and-shoot, noncontact, nondestructive, experimental stress analysis method based on thermoelasticity. Put simply, thermoelastic theory states that changes in an objects mechanical stress state cause changes in its physical dimensions and, hence, its surface temperature. Therefore, this chapter explains how to perform TSA for orthopaedic biomechanics applications, such as whole bones, fracture fixation devices, total joint replacements, and biomaterials, as well as how to analyze, present, and interpret results.

Biomechanical Measurement Error Can Be Caused by Fujifilm Thickness: A Theoretical, Experimental, and Computational Analysis

This is the first study to quantify the measurement error due to the physical thickness of Fujifilm for several material combinations relevant to orthopaedics. Theoretical and experimental analyses were conducted for cylinder-on-flat indentation over a series of forces (750 and 3000 N), cylinder diameters (0 to 80 mm), and material combinations (metal-on-metal, MOM; metal-on-polymer, MOP; metal-on-bone, MOB). For the scenario without Fujifilm, classic Hertzian theory predicted the true line-type contact width as WO = {(8FDcyl)/(πLcyl)[(1 − νcyl2)/Ecyl + (1 − νflat2)/Eflat]}1/2, where F is compressive force, Dcyl is cylinder diameter, Lcyl is cylinder length, νcyl and νflat are cylinder and flat Poissons ratios, and Ecyl and Eflat are cylinder and flat elastic moduli. For the scenario with Fujifilm, experimental measurements resulted in contact widths of WF = 0.1778 × F0.2273 × D0.2936 for MOM tests, WF = 0.0449 × F0.4664 × D0.4201 for MOP tests, and WF = 0.1647 × F0.2397 × D0.3394 for MOB tests, where F is compressive force and D is cylinder diameter. Fujifilm thickness error ratio WF/WO showed a nonlinear decrease versus cylinder diameter, whilst error graphs shifted down as force increased. Computational finite element analysis for several test cases agreed with theoretical and experimental data, respectively, to within 3.3% and 1.4%. Despite its wide use, Fujifilms measurement errors must be kept in mind when employed in orthopaedic biomechanics research.