Additive manufacturing functionally graded titanium structures with selective closed cell layout and controlled morphology

Sheydaeian, Esmat; Toyserkani, Ehsan

doi:10.1007/s00170-018-1815-2

Cited by 23 publications

(11 citation statements)

References 25 publications

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“…A binder jetting and material extrusion hybrid AM system was used to produce porosity graded Ti parts by providing encapsulated sacrificial polymer droplets at specified positions. The samples with changing porosity from 6% to 16% were obtained [80]. Graded titanium carbide preforms with hardness gradient of 700-1600 HV were fabricated as 4 layers by binder jet 3D-printing [81].…”

Section: Additive Manufacturing Of Functionally Graded Materialsmentioning

confidence: 99%

Vat Photopolymerization Additive Manufacturing of Functionally Graded Materials: A Review

Nohut

Schwentenwein²

2022

JMMP

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Functionally Graded Materials (FGMs) offer discrete or continuously changing properties/compositions over the volume of the parts. The widespread application of FGMs was not rapid enough in the past due to limitations of the manufacturing methods. Significant developments in manufacturing technologies especially in Additive Manufacturing (AM) enable us nowadays to manufacture materials with specified changes over the volume/surface of components. The use of AM methods for the manufacturing of FGMs may allow us to compensate for some drawbacks of conventional methods and to produce complex and near-net-shaped structures with better control of gradients in a cost-efficient way. Vat Photopolymerization (VP), a type of AM method that works according to the principle of curing liquid photopolymer resin layer-by-layer, has gained in recent years high importance due to its advantages such as low cost, high surface quality control, no need to support structures, no limitation in the material. This article reviews the state-of-art and future potential of using VP methods for FGM manufacturing. It was concluded that improvements in printer hardware setup and software, design aspects and printing methodologies will accelerate the use of VP methods for FGMs manufacturing.

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Section: Additive Manufacturing Of Functionally Graded Materialsmentioning

confidence: 99%

Vat Photopolymerization Additive Manufacturing of Functionally Graded Materials: A Review

Nohut

Schwentenwein²

2022

JMMP

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“…28 Functionally graded designs have been introduced as a solution through different design algorithms. 29 However, the majority of the literature remains focused on porous scaffolds with simple geometries for which their quasi-static compressive behavior is well documented. 30−34 Hip implants undergo rather different loading scenarios during daily activities, often a combination of tensile and compressive regions (due to the off-axis loading configuration).…”

Section: ■ Introductionmentioning

confidence: 99%

“…This complexity entails proper nonuniform distributions of porosity to design the implant locally with the desired functionalities to combine mechanobiological benefits obtained from different unit cell characteristics . Functionally graded designs have been introduced as a solution through different design algorithms . However, the majority of the literature remains focused on porous scaffolds with simple geometries for which their quasi-static compressive behavior is well documented. − Hip implants undergo rather different loading scenarios during daily activities, often a combination of tensile and compressive regions (due to the off-axis loading configuration). , Besides, the desired functionalities defined thus far mostly emphasize the mechanical aspects and lack sufficient understanding of the biological requirements.…”

Section: Introductionmentioning

confidence: 99%

Additively Manufactured Gradient Porous Ti–6Al–4V Hip Replacement Implants Embedded with Cell-Laden Gelatin Methacryloyl Hydrogels

Davoodi

Montazerian

Esmaeilizadeh

et al. 2021

ACS Appl. Mater. Interfaces

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Laser additive manufacturing has led to a paradigm shift in the design of next-generation customized porous implants aiming to integrate better with the surrounding bone. However, conflicting design criteria have limited the development of fully functional porous implants; increasing porosity improves body fluid/cell-laden prepolymer permeability at the expense of compromising mechanical stability. Here, functionally gradient porosity implants and scaffolds designed based on interconnected triply periodic minimal surfaces (TPMS) are demonstrated. High local porosity is defined at the implant/tissue interface aiming to improve the biological response. Gradually decreasing porosity from the surface to the center of the porous constructs provides mechanical strength in selective laser melted Ti−6Al−4V implants. The effect of unit cell size is studied to discover the printability limit where the specific surface area is maximized. Furthermore, mechanical studies on the unit cell topology effects suggest that the bending-dominated architectures can provide significantly enhanced strength and deformability, compared to stretching-dominated architectures. A finite element (FE) model developed also showed great predictability (within ∼13%) of the mechanical responses of implants to physical activities. Finally, in vitro biocompatibility studies were conducted for two-dimensional (2D) and threedimensional (3D) cases. The results of the 2D in conjunction with surface roughness show favored physical cell attachment on the implant surface. Also, the results of the 3D biocompatibility study for the scaffolds incorporated with a cell-laden gelatin methacryloyl (GelMA) hydrogel show excellent viability. The design procedure proposed here provides new insights into the development of porous hip implants with simultaneous high mechanical and biological responses.

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“…After having been printed, the product is sintered to improve its mechanical properties. So it is possible to fabricate parts out of bronze (Bai and Williams, 2015), ceramic materials (Gonzalez et al , 2016), stainless steel (Huang et al , 2017) and titanium (Sheydaeian and Toyserkani, 2018) among others. However, the available materials that must be gas atomized are still limited.…”

Section: Introductionmentioning

confidence: 99%

Casting of complex structures in aluminum using gypsum molds produced via binder jetting

Giorleo

Bonaventi

2021

RPJ

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Purpose The purpose of present paper is to enlarge the knowledge about the performance of gypsum powder to realize complex molds or cores for aluminum casting. Design/methodology/approach The research was divided into two activities: simple; and complex-part production capability. In the simple-part step, the performance of gypsum powder and the minimum mold thickness that would withstand the casting process. In the complex-part step, the authors first investigated the powder removability as a function of geometry complexity and then binder jetting performance was evaluated for the case of lattice-structure fabrication. Findings All the geometries tested withstand the casting process demonstrating the benefits in terms of complexity part design; however, the process suffers of all the typical defect of casting as misrun, porosity and cold shut. Originality/value The results found in this research improve the benefits related to additive manufacturing application in industrial environment and in particular to the binder jetting technology and the rapid casting approach.

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Additive manufacturing functionally graded titanium structures with selective closed cell layout and controlled morphology

Cited by 23 publications

References 25 publications

Vat Photopolymerization Additive Manufacturing of Functionally Graded Materials: A Review

Vat Photopolymerization Additive Manufacturing of Functionally Graded Materials: A Review

Additively Manufactured Gradient Porous Ti–6Al–4V Hip Replacement Implants Embedded with Cell-Laden Gelatin Methacryloyl Hydrogels

Casting of complex structures in aluminum using gypsum molds produced via binder jetting

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