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Predicting the output dimensions, porosity and elastic modulus of additive manufactured biomaterial structures targeting orthopedic implants

Publication . Bartolomeu, F.; Fonseca, J.; Peixinho, N.; Alves, N.; Gasik, M.; Silva, F.S.; Miranda, G.

SLM accuracy for fabricating porous materials is a noteworthy hindrance when aiming to obtain biomaterial cellular structures owing precise geometry, porosity, open-cells dimension and mechanical properties as outcomes. This study provides a comprehensive characterization of seventeen biomaterial Ti6Al4V-based structures in which experimental and numerical investigations (compression stress-strain tests) were carried out. Monomaterial Ti6Al4V cellular structures and multi-material Ti6Al4V-PEEK cellular structures were designed, produced by SLM and characterized targeting orthopedic implants. In this work, the differences between the CAD design and the as-produced Ti6Al4V-based structures were obtained from image analysis and were used to develop predictive models. The results showed that dimensional deviations inherent to SLM fabrication are systematically found for different dimensional ranges. The present study proposes several mathematical models, having high coefficients of determination, that estimate the real dimensions, porosity and elastic modulus of Ti6Al4V-based cellular structures as function of the CAD model. Moreover, numerical analysis was performed to estimate the octahedral shear strain for correlating with bone mechanostat theory limits. The developed models can help engineers to design and obtain near-net shape SLM biomaterials matching the desired geometry, opencells dimensions, porosity and elastic modulus. The obtained results show that by using these AM structures design it is possible to fabricate components exhibiting a strain and elastic modulus that complies with that of bone, thus being suitable for orthopedic implants.

2019Journal article

Open access

Multi-material Ti6Al4V & PEEK cellular structures produced by Selective Laser Melting and Hot Pressing: A tribocorrosion study targeting orthopedic applications

Publication . Bartolomeu, F.; Buciumeanu, M.; Costa, M.M.; Alves, N.; Gasik, M.; Silva, F.S.; Miranda, G.

Ti6Al4V-alloy is commonly used in dental and orthopedic applications where tribochemical reactions occur at material/bone interface. These reactions are one of the main concerns regarding Ti6Al4V implants due to the generation of wear particles, linked to the release of metallic ions in toxic concentration which occurs when TiO2 passive film is destroyed by means of wear and corrosion simultaneously. In the present study, a multi-material Ti6Al4V-PEEK cellular structure is proposed. Selective Laser Melting technique was used to produce Ti6Al4V dense and cellular structured specimens, whilst Hot-Pressing technique was employed to obtain multi-material Ti6Al4V-PEEK structures. This study investigates the tribocorrosion behavior of these materials under reciprocating sliding, comparing them with commercial forged Ti6Al4V. Open-circuit-potential was measured before, during and after sliding while dynamic coefficient of friction was assessed during sliding. The results showed an improved wear resistance and a lower tendency to corrosion for the multi-material Ti6Al4V-PEEK specimens when compared to dense and cellular structures mono-material specimens. This multi-material solution gathering Ti6Al4V and PEEK, besides being able to withstand the loads occurring after implantation on dental and orthopedic applications, is a promising alternative to fully dense metals once it enhances the tribocorrosion performance.

2019Journal article

Open access

A study on the production of thin-walled Ti6Al4V parts by selective laser melting

Publication . Miranda, G.; Faria, S.; Bartolomeu, F.; Pinto, E.; Alves, N.; Peixinho, N.; Gasik, M.; Silva, F.S.

Selective Laser Melting (SLM) is an extremely versatile technology especially suited for the manufacturing of thin-walled parts. Micro-sized parts are highly influenced and dependent on the SLM processing parameters; thus being indispensable to assess the influence of processing parameters on SLM fabrication, as isolated parameters but also their interactions. In this study, the influence of SLM laser power and scanning speed on Ti6Al4V micropillars and micro-plates thickness was assessed by applying response surface methodology (RSM). These analyses resulted in four models that exhibit complex correlations of SLM process parameters, with non-linear equations, having coefficients of determination that assess the quality of the models. These developed models are accurate tools that can be used to optimize the micro manufacture of Ti6Al4V thin-walled parts by SLM.

2019Journal article

Open access

Ti6Al4V-PEEK multi-material structures – design, fabrication and tribological characterization focused on orthopedic implants

Publication . Bartolomeu, F.; Abreu, C.S.; Moura, C.G.; Costa, M.M.; Alves, N.; Silva, F.S.; Miranda, G.

A multi-material concept that gathers Ti6Al4V and PEEK properties in a cellular structured component was designed, fabricated and investigated targeting hip implants. SLM and pressure assisted injection techniques were used to obtain Ti6Al4V-PEEK multi-material structures. Aiming to reproduce to some extension the tribological phenomena occurring during and after hip implant insertion, five tribological tests were outlined and performed. The obtained results showed that the presence of PEEK on the Ti6Al4V-PEEK cellular structures led to a substantial improvement on the wear resistance (62% reduction in the mass loss) when compared to the material currently available on market for hip implants. The multi-material solution here investigated shows a good compromise between the primary stability after implant insertion and the wear performance.

2019Journal article

Open access

Tribological behavior of bioactive multi-material structures targeting orthopedic applications

Publication . Costa, M.M.; Bartolomeu, F.; Alves, N.; Silva, F.S.; Miranda, G.

The following study proposes a multi-material solution in which Ti6Al4V cellular structures produced by Selective Laser Melting are impregnated with bioactive materials (hydroxyapatite or β-tricalcium phosphate) using press and sintering technique. To assess the tribological response of these structures, an alumina plate was used as a counterpart in a flat-on-flat reciprocating sliding test. Ti6Al4V cellular structures impregnated with bioactive materials displayed the highest wear resistance when compared with the unreinforced structures. Among the bioactive structures, Ti6Al4V cellular structures impregnated with βTCP were the ones with higher wear resistance, having the lowest weight loss. Hence, these structures are promising multifunctional solutions for load-bearing applications by gathering suitable mechanical properties (strength and stiffness); bioactive properties and in addition an improved wear performance.

2019Journal article

Open access