Direct metal fabrication of titanium implants with tailored materials and mechanical properties using electron beam melting technology

Harrysson, Ola L. A.; Cansizoglu, Omer; Marcellin‐Little, Denis J.; Cormier, Denis; West, Harvey

doi:10.1016/j.msec.2007.04.022

Cited by 375 publications

(232 citation statements)

References 29 publications

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“…These geometries have been demonstrated elsewhere and fabricated by electron beam melting [13][14][15]. The unit cells of these structures are shown in Figure 3.…”

Section: Structural Designsmentioning

confidence: 99%

A Comparison of Bending Properties for Cellular Core Sandwich Panels

Yang¹,

Harrysson²,

West³

et al. 2013

MSA

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In this study, various sandwich panel structures with different reticulate lattice core geometries were designed and then fabricated in titanium via the electron beam melting (EBM) process. Bending tests were performed on the titanium samples, and mechanical properties such as modulus, bending strength, and energy absorption were evaluated. Different failure mechanisms were observed, and it was found that sandwich structures with auxetic cores exhibited more homogeneous deflection and bending compliance compared with other structures. It was also demonstrated that properties of auxetic sandwich structures can be tailored using different cell structure geometries to suit the needs of a given design application. Furthermore, it was found that other 3D cellular sandwich structures can also exhibit high stiffness and strength, which is desirable in potential applications.

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“…These geometries have been demonstrated elsewhere and fabricated by electron beam melting [13][14][15]. The unit cells of these structures are shown in Figure 3.…”

Section: Structural Designsmentioning

confidence: 99%

A Comparison of Bending Properties for Cellular Core Sandwich Panels

Yang¹,

Harrysson²,

West³

et al. 2013

MSA

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show abstract

“…During the optimization procedure, the values of mean porosity and pore size are selected to ensure bone ingrowth (Bragdon et al, 2004;Harrysson et al, 2008), and the minimum thickness of the cell walls is determined by the resolution of the manufacturing process, i.e. the manufacturing limits.…”

Section: Fatigue Design Of a Hip Implant With Controlled Lattice Micrmentioning

confidence: 99%

Fatigue design of a mechanically biocompatible lattice for a proof-of-concept femoral stem

Khanoki

Pasini

2013

Journal of the Mechanical Behavior of Biomedical Materials

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A methodology is proposed to design a spatially periodic microarchitectured material for a twodimensional femoral implant under walking gait conditions. The material is composed of a graded lattice with controlled property distribution that minimizes concurrently bone resorption and interface failure. The periodic microstructure of the material is designed for fatigue fracture caused by cyclic loadings on the hip joint as a result of walking. The bulk material of the lattice is Ti6AL4V and its microstructure is assumed free of defects. The Soderberg diagram is used for the fatigue design under multiaxial loadings. Two cell topologies, square and Kagome, are chosen to obtain optimized property gradients for a two-dimensional implant. Asymptotic homogenization (AH) theory is used to address the multiscale mechanics of the implant as well as to capture the stress and strain distribution at both the macro and the microscale. The microstress distribution found with AH is also compared with that obtained from a detailed finite element analysis. For the maximum value of the von Mises stress, we observe a deviation of 18.6 % in unit cells close to the implant boundary, where the AH assumption of spatial periodicity of the fluctuating fields ceases to hold. In the second part of the paper, the metrics of bone resorption and interface shear stress are used to benchmark the graded cellular implant with existing prostheses made of fully dense titanium implant.The results show that the amount of initial postoperative bone loss for square and kagome lattice implants decreases, respectively, by 53.8% and 58%. In addition, the maximum shear interface failure at the distal end is significantly reduced by about 79%.A set of proof-of-concepts of planar implants have been fabricated via Electron Beam Melting (EBM) to demonstrate the manufacturability of Ti6AL4V into graded lattices with alternative cell size. Optical microscopy has been used to measure the morphological parameters of the cellular microstructure, including cell wall thickness and pore size, and compared them with the nominal values. No sign of fracture or incomplete cell walls was observed, an assessment that shows the satisfactory metallurgical bond of cell walls and the structural integrity of the implants.

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“…The machinability of the SLM is weakly related to the complexity of the structure for each part, which forms a good complement to conventional manufacturing processes [10,11]. The powerful free-formability offered by SLM shows great potential in making advanced lightweight and functional structures, which are highly desired by engineering sectors.…”

Section: Introductionmentioning

confidence: 99%

Discrete Optimization of Internal Part Structure via SLM Unit Structure-Performance Database

Tang

Zhang

Liang

et al. 2018

Metals

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Abstract:The structural optimization of the internal structure of parts based on three-dimensional (3D) printing has been recognized as being important in the field of mechanical design. The purpose of this paper is to present a creation of a unit structure-performance database based on the selective laser melting (SLM), which contains various structural units with different functions and records their structure and performance characteristics so that we can optimize the internal structure of parts directly, according to the database. The method of creating the unit structure-performance database was introduced in this paper and several structural units of the unit structure-performance database were introduced. The bow structure unit was used to show how to create the structure-performance database of the unit as an example. Some samples of the bow structure unit were designed and manufactured by SLM. These samples were tested in the WDW-100 compression testing machine to obtain their performance characteristics. After this, the paper collected all data regarding unit structure parameters, weight, performance characteristics, and other data; and, established a complete set of data from the bow structure unit for the unit structure-performance database. Furthermore, an aircraft part was reconstructed conveniently to be more lightweight according to the unit structure-performance database. Its weight was reduced by 36.8% when compared with the original structure, while the strength far exceeded the requirements.

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Direct metal fabrication of titanium implants with tailored materials and mechanical properties using electron beam melting technology

Cited by 375 publications

References 29 publications

A Comparison of Bending Properties for Cellular Core Sandwich Panels

A Comparison of Bending Properties for Cellular Core Sandwich Panels

Fatigue design of a mechanically biocompatible lattice for a proof-of-concept femoral stem

Discrete Optimization of Internal Part Structure via SLM Unit Structure-Performance Database

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