A comprehensive review on additive manufacturing of medical devices

Silva, Leonardo Rosa Ribeiro da; Sales, Wisley Falco; Campos, Felipe dos Anjos Rodrigues; Sousa, João; Davis, Rahul; Singh, Abhishek; Coelho, Reginaldo Teixeira; Borgohain, Bhaskar

doi:10.1007/s40964-021-00188-0

Cited by 38 publications

(12 citation statements)

References 172 publications

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“…These interconnected pores also present remarkable future capabilities as scaffolds for tissue engineering in vitro before surgery. Even though they are mainly produced by powder metallurgy [ 285 ] and additive manufacturing [ 286 ], non-traditional subtractive manufacturing processes may also be implemented for this purpose. Sales et al [ 269 ] were able to produce a porous perovskite layer on the surface of Ti-6Al-4 V alloy through EDM.…”

Section: Future Trendsmentioning

confidence: 99%

A comprehensive review on metallic implant biomaterials and their subtractive manufacturing

Davis

Singh

Jackson

et al. 2022

Int J Adv Manuf Technol

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112

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There is a tremendous increase in the demand for converting biomaterials into high-quality industrially manufactured human body parts, also known as medical implants. Drug delivery systems, bone plates, screws, cranial, and dental devices are the popular examples of these implants - the potential alternatives for human life survival. However, the processing techniques of an engineered implant largely determine its preciseness, surface characteristics, and interactive ability with the adjacent tissue(s) in a particular biological environment. Moreover, the high cost-effective manufacturing of an implant under tight tolerances remains a challenge. In this regard, several subtractive or additive manufacturing techniques are employed to manufacture patient-specific implants, depending primarily on the required biocompatibility, bioactivity, surface integrity, and fatigue strength. The present paper reviews numerous non-degradable and degradable metallic implant biomaterials such as stainless steel (SS), titanium (Ti)-based, cobalt (Co)-based, nickel-titanium (NiTi), and magnesium (Mg)-based alloys, followed by their processing via traditional turning, drilling, and milling including the high-speed multi-axis CNC machining, and non-traditional abrasive water jet machining (AWJM), laser beam machining (LBM), ultrasonic machining (USM), and electric discharge machining (EDM) types of subtractive manufacturing techniques. However, the review further funnels down its primary focus on Mg, NiTi, and Ti-based alloys on the basis of the increasing trend of their implant applications in the last decade due to some of their outstanding properties. In the recent years, the incorporation of cryogenic coolant-assisted traditional subtraction of biomaterials has gained researchers’ attention due to its sustainability, environment-friendly nature, performance, and superior biocompatible and functional outcomes fitting for medical applications. However, some of the latest studies reported that the medical implant manufacturing requirements could be more remarkably met using the non-traditional subtractive manufacturing approaches. Altogether, cryogenic machining among the traditional routes and EDM among the non-traditional means along with their variants, were identified as some of the most effective subtractive manufacturing techniques for achieving the dimensionally accurate and biocompatible metallic medical implants with significantly modified surfaces.

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Section: Future Trendsmentioning

confidence: 99%

A comprehensive review on metallic implant biomaterials and their subtractive manufacturing

Davis

Singh

Jackson

et al. 2022

Int J Adv Manuf Technol

Self Cite

112

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“…Additive manufacturing (AM) technologies are considered suitable manufacturing solutions for different industrial applications ranging from aerospace to biomedical sectors, even for industry 4.0. In the biomedical field, researchers are consistently working to fabricate functional parts to mimic the natural functioning of soft and hard tissues in the human body [ 1 , 2 ]. Recently, the promising role of additive manufacturing to fabricate various biomedical products during the COVID-19 pandemic cannot be overlooked [ 3 ].…”

Section: Introductionmentioning

confidence: 99%

Additive manufacturing for biomedical applications: a review on classification, energy consumption, and its appreciable role since COVID-19 pandemic

et al. 2022

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The exponential rise of healthcare problems like human aging and road traffic accidents have developed an intrinsic challenge to biomedical sectors concerning the arrangement of patient-specific biomedical products. The additively manufactured implants and scaffolds have captured global attention over the last two decades concerning their printing quality and ease of manufacturing. However, the inherent challenges associated with additive manufacturing (AM) technologies, namely process selection, level of complexity, printing speed, resolution, biomaterial choice, and consumed energy, still pose several limitations on their use. Recently, the whole world has faced severe supply chain disruptions of personal protective equipment and basic medical facilities due to a respiratory disease known as the coronavirus (COVID-19). In this regard, local and global AM manufacturers have printed biomedical products to level the supply–demand equation. The potential of AM technologies for biomedical applications before, during, and post-COVID-19 pandemic alongwith its relation to the industry 4.0 (I4.0) concept is discussed herein. Moreover, additive manufacturing technologies are studied in this work concerning their working principle, classification, materials, processing variables, output responses, merits, challenges, and biomedical applications. Different factors affecting the sustainable performance in AM for biomedical applications are discussed with more focus on the comparative examination of consumed energy to determine which process is more sustainable. The recent advancements in the field like 4D printing and 5D printing are useful for the successful implementation of I4.0 to combat any future pandemic scenario. The potential of hybrid printing, multi-materials printing, and printing with smart materials, has been identified as hot research areas to produce scaffolds and implants in regenerative medicine, tissue engineering, and orthopedic implants.

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“…Minimal production of wastes makes this technology environmentalfriendly [6] and provides an advantage towards sustainable manufacturing compared to traditional manufacturing methods. These features have attracted various manufacturing sectors [7], such as biomedical/dental [8][9][10], automobile [11], aviation [12], and construction [13], from the early stages of AM development. Many more sectors are adopting AM, making the manufacturing process economically affordable and environmentally sustainable (Fig.…”

Section: Introductionmentioning

confidence: 99%

Additive manufacturing by digital light processing: a review

et al. 2022

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Additive manufacturing is a layer-by-layer strategy enabling the advanced design and fabrication of complex 3D objects and structures, overcoming geometry limitations and reducing waste production compared to conventional technologies. Among various additive manufacturing technologies, digital light processing (DLP), is an additive manufacturing technology used to print photopolymer parts, using a projected light source to cure an entire layer at once. Initially developed for pure resins, recent advances have demonstrated the potential of DLP in the polymerization of ceramic and metal-loaded suspensions, enabling the fabrication of ceramic and metal components after proper debinding and sintering. Such flexibility increases the potential of DLP for different applications, ranging from dental implants and bone scaffolds to smart biomaterials for soft robotics, smart wearables, and microfluidic devices. The review provides an overview of DLP technology and its recent advances; specifically, the review covers the photopolymer properties, the ceramic and metallic feedstock preparation, and the light-matter interaction mechanism underpinning the printing and post-processing steps. Finally, a description of the current application is provided and complemented with future perspectives.

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A comprehensive review on additive manufacturing of medical devices

Cited by 38 publications

References 172 publications

A comprehensive review on metallic implant biomaterials and their subtractive manufacturing

A comprehensive review on metallic implant biomaterials and their subtractive manufacturing

Additive manufacturing for biomedical applications: a review on classification, energy consumption, and its appreciable role since COVID-19 pandemic

Additive manufacturing by digital light processing: a review

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