Coating needles with metallic glass to overcome fracture toughness and trauma: Analysis on porcine tissue and polyurethane rubber

Diyatmika

Tseng

et al. 2019

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In this study, we sought to enhance the cutting properties of the various blades by coating them with Zr- and Fe-based thin film metallic glasses (TFMGs) to a thickness of 234–255 nm via sputter deposition. In oil-repellency/sliding tests on kitchen blades, the sliding angle and friction forces were as follows: bare blades (31.6°) and (35 µN), Ti-coated blades (20.3°) and (23.7 µN), and Z-TFMG coated blades (16.2°) and (19.2 µN). Comparisons were conducted with bare blades and those with a Teflon coating (a low-friction material commonly used for the coating of microtome blades). We also found that the Teflon coating reduced the cutting forces of an uncoated microtome blade by ~80%, whereas the proposed Z-TFMG achieved a ~51% reduction. The Z-TFMG presented no indications of delamination after being used 30 times for cutting; however, the Teflon coating proved highly susceptible to peeling and the bare blade was affected by surface staining. These results demonstrate the efficacy of the TFMG coating in terms of low friction, non-stick performance, and substrate adhesion. The performance of Z-TFMG and F-TFMG was also evaluated in split-thickness skin graft surgery using dermatome blades aimed at elucidating the influence of TFMG coatings on the healing of surgical incisions. When tested repeatedly on hairless skin, the surface roughness of uncoated blades increased by approximately 70%, whereas the surface roughness of TFMG-coated blades increases by only 8.6%. In the presence of hair, the surface roughness of uncoated blades increased by approximately ~108%, whereas the surface roughness of TFMG-coated blades increases by only ~23%. By Day 7, the wounds produced using TFMG-coated blades were noticeably smaller than those produced using uncoated blades, and these effects were particularly evident in hairy samples. This is a clear demonstration of the efficacy of TFMG surface coatings in preserving the cutting quality of surgical instruments.

Section: Introductionmentioning

confidence: 97%

Coating Cutting Blades with Thin-Film Metallic Glass to Enhance Sharpness

Diyatmika

Tseng

et al. 2019

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“…Multicomponent amorphous metallic films are an attractive alternative to conventional alloys, thanks to their smooth surface, high hardness, and high ductility as well as low-temperature processing (e.g., sputter deposition). The low CoF (~ 0.05) and non-stick properties of TFMGs make them ideal coatings for knives and needles applied to biological materials 11 – 14 . In previous studies, we reported on the durability of these devices, as evidenced by their low cutting and insertion forces after being used multiple times.…”

Section: Introductionmentioning

confidence: 99%

Metallic glass coating for improving diamond dicing performance

Lai

Yiu

et al. 2020

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This is the first report on the coating of diamond dicing blades with metallic glass (MG) coating to reduce chipping when used to cut Si, SiC, sapphire, and patterned sapphire substrates (PSS). The low coefficient-of-friction (CoF) of Zr-based MG-coated dicing blades was shown to reduce the number and size of chips, regardless of the target substrate. Overall, SiC, sapphire and PSS were most affected by chipping, due to the fact that higher cutting forces were needed for the higher hardness of SiC, sapphire and PSS. Compared to the bare blade, the MG coating provided the following reductions in chipping area: Si (~ 23%), SiC (~ 36%), sapphire (~ 45%), and PSS (~ 33%). The proposed coating proved particularly effective in reducing chips of larger size (> 41 µm in chipping width), as indicated by an ~ 80% reduction when cutting sapphire. Small variations in kerf angle and depth demonstrate the durability of the coated blades, which would no doubt enhance consistency in dicing performance and extend the blade lifespan. Finite-element modeling revealed significant reductions in tensile stress and elastic-plastic deformation during dicing, thanks to a lower CoF. Diamond abrasive blades are widely used to cut silicon, SiC, and sapphire dies in the manufacture of semiconductors and optoelectronic devices 1-3. The brittleness of these hard workpieces inevitably leads to chipping and/ or other types of damage, which might also give rise to failure in dies and chips, eventually causes yield loss 4-6. Space between dies, called streets is usually spared to accommodate chipping on both sides of the dicing kerf. Yet this approach reduces the number of die per wafer and thus is a waste of very expensive substrate material. Researchers have sought to improve cutting quality by adjusting the concentration and size of diamond grit 7,8 as well as the bonding material 7,9. Note also that it is essential to minimize the number and size of chips due to the fact that even undetectable chipping provides sites for potential failure under the application of a strong electrical field. Controlling the factors that lead to chipping also has benefits for the environment, by reducing the amount of water required for cooling and decreasing the amount of waste debris. This is the first report on coating diamond dicing blades with thin film metallic glass (TFMG) to reduce chipping when used to cut Si, SiC, sapphire, and patterned sapphire substrates (PSS). We focused on these workpieces due to their wide-scale use in semiconductors and light-emitting diodes. This is the first application of a coating on diamond dicing blades to enhance dicing performance. The thin film metallic glass (TFMG) coating in this study has a low coefficient of friction (CoF) and notable glass transition and crystallization characteristics 10,11. Multicomponent amorphous metallic films are an attractive alternative to conventional alloys, thanks to their smooth surface, high hardness, and high ductility as well as low-temperature processing (e.g., sputter deposition). T...

“…Any close inspection of stainless steel surfaces is bound to reveal a large number of scratches, which tend to promote cell adhesion. In previous studies, we demonstrated the benefits of applying thin film metallic glass (TFMG) to surgical blades and needles in terms of antibacterial properties, sharpness, and durability [3][4][5][6] . Metallic glasses (MGs) (i.e., amorphous metallic alloys) are noncrystalline metals, which lack long-range atomic periodicity associated with the rapid quench rates used in fabrication.…”

mentioning

confidence: 99%

Preclinical studies of non-stick thin film metallic glass-coated syringe needles

Bai

Chang

2020

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Our objective in this study was to determine the biocompatibility and hemocompatibility of thin film metallic glass (TFMG) and its potential use in hypodermic needles for intramuscular or intravenous injection. Mouse and rabbit models were employed under approval from the Institutional Animal Care and Use Committee (n = 5/group, two groups in total for both animal models). Platelet-rich plasma (PRP) was collected from the whole blood of rabbits (ear vein) without anti-coagulant for use in in vitro coagulation tests. Histological analysis and optical microscopy were used to assess the endothelial structure of the inner lining of veins after being punctured with needles and detained for 3 days. Histological analysis of ear vein sections revealed that the extent of endothelial damage after puncturing with a TFMG-coated needle was 33% less than that produced by bare needles. Our results confirm that the deposition of a thin TFMG layer (e.g., Zr53Cu33Al9Ta5) on the surface of hypodermic needle can have remarkably clinical benefits, including anti-adhesion, reduced invasion, and minimal endothelial damage. Our results also confirm the good biocompatibility and hemocompatibility of the TFMG coatings.