A Brief Review of Current Trends in the Additive Manufacturing of Orthopedic Implants with Thermal Plasma-Sprayed Coatings to Improve the Implant Surface Biocompatibility
Abstract:The demand for orthopedic implants is increasing, driven by a rising number of young patients seeking an active lifestyle post-surgery. This has led to changes in manufacturing requirements. Joint arthroplasty operations are on the rise globally, and recovery times are being reduced by customized endoprostheses that promote better integration. Implants are primarily made from metals and ceramics such as titanium, hydroxyapatite, zirconium, and tantalum. Manufacturing processes, including additive manufacturing… Show more
“…In recent decades, the medical implant industry has undergone profound transformations driven by the pursuit of advanced medical implant technologies to reduce implant failure after joint replacement, speed up implant healing, and prolong the life of implants in the patient's body. Meanwhile, the achievement of implant materials hinges on mechanical behaviors, biocompatibility, and corrosion resistance [1][2][3][4].…”
Section: Introductionmentioning
confidence: 99%
“…Anodization further augments corrosion resistance and biocompatibility, incorporating bioactive substances. Laser treatment creates specific patterns for bone integration, while plasma spraying offers precise control over microstructure, including essential porosity and roughness for optimal cell adhesion and implant longevity [3,4].…”
Section: Introductionmentioning
confidence: 99%
“…Therefore, the initial reaction of living tissue to the implant material depends on the properties of the implant surface. To provide the best outcomes, different techniques have been used to manufacture and develop biomaterial applications, such as gas abrasive surface treatment [1,2,4,12], powder technology [18,19], 3D printing technologies [2,4,13,17], vacuum plasma spraying (VPS) [11,12], thermal plasma spraying (TPS) of coatings from biocompatible materials on endoprosthetic implants [20][21][22][23][24], etc.…”
Section: Introductionmentioning
confidence: 99%
“…Nowadays, not only the choice of materials for coating medical implants and endoprostheses but also the optimal porosity and roughness of these coatings are the subject of debate among researchers; a detailed discussion of the problem can be found in the review article by Alontseva et al [4]. Porosity or surface roughness parameters are not included in international standards for medical implant coatings.…”
This study investigates the in vitro biocompatibility, corrosion resistance, and adhesion strength of a gas abrasive-treated Ti6Al4V alloy, alongside microplasma-sprayed titanium and tantalum coatings. Employing a novel approach in selecting microplasma spray parameters, this study successfully engineers coatings with tailored porosity, roughness, and over 20% porosity with pore sizes up to 200 μm, aiming to enhance bone in-growth and implant integration. This study introduces an innovative methodology for quantifying surface roughness using laser electron microscopy and scanning electron microscopy, facilitating detailed morphological analysis of both the substrate and coatings. Extensive evaluations, including tests for in vitro biocompatibility, corrosion resistance, and adhesive strength, revealed that all three materials are biocompatible, with tantalum coatings exhibiting superior cell proliferation and osteogenic differentiation, as well as the highest corrosion resistance. Titanium coatings followed closely, demonstrating favorable osteogenic properties and enhanced roughness, which is crucial for cell behavior and attachment. These coatings also displayed superior tensile adhesive strengths (27.6 ± 0.9 MPa for Ti and 28.0 ± 4.9 MPa for Ta), surpassing the ISO 13179-1 standard and indicating a robust bond with the substrate. Our findings offer significant advancements in biomaterials for medical implants, introducing microplasma spraying as a versatile tool for customizing implant coatings, particularly emphasizing the superior performance of tantalum coatings in terms of biocompatibility, osteogenic potential, and corrosion resistance. This suggests that tantalum coatings are a promising alternative for enhancing the performance of metal implants, especially in applications demanding high biocompatibility and corrosion resistance.
“…In recent decades, the medical implant industry has undergone profound transformations driven by the pursuit of advanced medical implant technologies to reduce implant failure after joint replacement, speed up implant healing, and prolong the life of implants in the patient's body. Meanwhile, the achievement of implant materials hinges on mechanical behaviors, biocompatibility, and corrosion resistance [1][2][3][4].…”
Section: Introductionmentioning
confidence: 99%
“…Anodization further augments corrosion resistance and biocompatibility, incorporating bioactive substances. Laser treatment creates specific patterns for bone integration, while plasma spraying offers precise control over microstructure, including essential porosity and roughness for optimal cell adhesion and implant longevity [3,4].…”
Section: Introductionmentioning
confidence: 99%
“…Therefore, the initial reaction of living tissue to the implant material depends on the properties of the implant surface. To provide the best outcomes, different techniques have been used to manufacture and develop biomaterial applications, such as gas abrasive surface treatment [1,2,4,12], powder technology [18,19], 3D printing technologies [2,4,13,17], vacuum plasma spraying (VPS) [11,12], thermal plasma spraying (TPS) of coatings from biocompatible materials on endoprosthetic implants [20][21][22][23][24], etc.…”
Section: Introductionmentioning
confidence: 99%
“…Nowadays, not only the choice of materials for coating medical implants and endoprostheses but also the optimal porosity and roughness of these coatings are the subject of debate among researchers; a detailed discussion of the problem can be found in the review article by Alontseva et al [4]. Porosity or surface roughness parameters are not included in international standards for medical implant coatings.…”
This study investigates the in vitro biocompatibility, corrosion resistance, and adhesion strength of a gas abrasive-treated Ti6Al4V alloy, alongside microplasma-sprayed titanium and tantalum coatings. Employing a novel approach in selecting microplasma spray parameters, this study successfully engineers coatings with tailored porosity, roughness, and over 20% porosity with pore sizes up to 200 μm, aiming to enhance bone in-growth and implant integration. This study introduces an innovative methodology for quantifying surface roughness using laser electron microscopy and scanning electron microscopy, facilitating detailed morphological analysis of both the substrate and coatings. Extensive evaluations, including tests for in vitro biocompatibility, corrosion resistance, and adhesive strength, revealed that all three materials are biocompatible, with tantalum coatings exhibiting superior cell proliferation and osteogenic differentiation, as well as the highest corrosion resistance. Titanium coatings followed closely, demonstrating favorable osteogenic properties and enhanced roughness, which is crucial for cell behavior and attachment. These coatings also displayed superior tensile adhesive strengths (27.6 ± 0.9 MPa for Ti and 28.0 ± 4.9 MPa for Ta), surpassing the ISO 13179-1 standard and indicating a robust bond with the substrate. Our findings offer significant advancements in biomaterials for medical implants, introducing microplasma spraying as a versatile tool for customizing implant coatings, particularly emphasizing the superior performance of tantalum coatings in terms of biocompatibility, osteogenic potential, and corrosion resistance. This suggests that tantalum coatings are a promising alternative for enhancing the performance of metal implants, especially in applications demanding high biocompatibility and corrosion resistance.
“…Recently, additive manufacturing has become increasingly important in medicine and pharmacy [1]. In pharmacy it enables the creation of new drug delivery systems [2][3][4], and in medicine is being used in tissue engineering [5,6], cardiology [7], dentistry [8], prosthetics [9], neurology [10], orthopaedics [11], to produce precision surgical instruments [12], implants [13], medical devices [14] and anatomical structure models [15].…”
Wrist-hand orthosis was developed using PolyJet Matrix (PJM) and Fused Filament Fabrication (FFF) additive technologies. MED610 and PLACTIVE were used as the filament. The orthosis was divided into parts A and B. The accuracy of both parts was checked using an optical scanner. The PJM method was more accurate. The compressive strength and stress relaxation of the orthosis were also tested. Greater strength was achieved for part A made using PJM technology, and for part B made using FFF technology.
In this experimental study, the initial phase involved preparing composite structures with various mix ratios using the Ti‐6Al‐4V alloy, widely used in clinical applications, in conjunction with ZrO2 and hydroxyapatite (HA) synthesized via the precipitation method, employing powder metallurgy techniques. Subsequently, the microstructures of the resultant hybrid composite materials were imaged, and x‐ray diffraction (XRD) phase analyses were conducted. In the final phase of the experimental work, tests were performed to determine the biocompatibility properties of the hybrid composites. For this purpose, cytotoxicity and genotoxicity assays were carried out. The tests and examinations revealed that structures compatible both morphologically and elementally were obtained with no phase transformations that could disrupt the structure. The incorporation of ZrO2 into the Ti‐6Al‐4V alloy was observed to enhance cell viability values. The value of 98.25 ± 0.42 obtained by adding 20% ZrO2 gave the highest cell viability result. The addition of HA into the hybrid structures further increased the cell viability values by approximately 10%. All viability values for both HA‐added and HA‐free groups were obtained above the 70% viability level defined in the standard. According to the genotoxicity test results, the highest cytokinesis‐block proliferation index values were obtained as 1.666 and 0.620 in structures containing 20% ZrO2 and 10% ZrO2 + 10% HA, respectively. Remarkably, all fabricated composite and hybrid composite materials surpassed established biocompatibility standards and exhibited nontoxic and nongenotoxic properties. This comprehensive study contributes vital insights for future biomechanical and other in vitro and in vivo experiments, as it meticulously addresses fundamental characterization parameters crucial for medical device development.Research Highlights
Support of optimum doping rates ions on hybrid composites and concentrations.
Development of uniform surface appearance and distributions/orientations of microcrystals on ceramic compounds
Improvement of cell viability and desired increase in biocompatibility with the doping of HA.
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