Fabrication Of Scaffolds From Ti6Al4V Powders Using The Computer Aided Laser Method

Abstract

The aim of the research, the results of which are presented in the paper, is to fabricate, by Selective Laser Melting (SLM), a metallic scaffold with Ti6Al4V powder based on a virtual model corresponding to the actual loss of a patient's craniofacial bone. A plaster cast was made for a patient with a palate recess, and the cast was then scanned with a 3D scanner to create a virtual 3D model of a palate recess, according to which a 3D model of a solid implant was created using specialist software. The virtual 3D solid implant model was converted into a 3D porous implant model after designing an individual shape of the unit cell conditioning the size and three-dimensional shape of the scaffold pores by multiplication of unit cells. The data concerning a virtual 3D porous implant model was transferred into a selective laser melting (SLM) device and a metallic scaffold was produced from Ti6Al4V powder with this machine, which was subjected to surface treatment by chemical etching. An object with certain initially adopted assumptions, i.e. shape and geometric dimensions, was finally achieved, which perfectly matches the patient bone recesses. The scaffold created was subjected to micro-and spectroscopic examinations.Keywords: biomimetic materials, CAMD, scaffolds, SLM, Ti6Al4V powders, SEM, EDS Celem badań, których wyniki zaprezentowano w artykule jest wytworzenie, metodą selektywnego topienia laserowego (SLM), scaffoldu metalowego z proszku Ti6Al4V na podstawie wirtualnego modelu odpowiadającego rzeczywistemu ubytkowi kości twarzoczaszki pacjenta. Od pacjenta z ubytkiem podniebienia pobierano wycisk gipsowy, który następnie zeskanowano za pomocą skanera 3D, w celu uzyskania wirtualnego modelu 3D ubytku podniebienia, na podstawie którego z użyciem specjalistycznego oprogramowania utworzono model 3D litego implantu. Po zaprojektowaniu indywidualnego kształtu komórki jednostkowej, determinującej wielkość i trójwymiarowy kształt porów scaffoldu, poprzez multiplikację komórek jednostkowych przekształcono wirtualny model 3D implantu litego w model 3D implantu porowatego. Dane dotyczące wirtualnego modelu 3D implantu porowatego przetransferowano do urządzenia służącego do selektywnego topienia laserowego (SLM) i z użyciem tej maszyny z proszku Ti6Al4V wytworzono metalowy scaffold, który poddano obróbce powierzchniowej poprzez trawienie chemiczne. Finalnie otrzymano obiekt o założonych na wstępie: kształcie i wymiarach geometrycznych, które idealnie odpowiadają ubytkowi kości pacjenta. Wytworzony scaffold poddano badaniom mikroi spektroskopowym.

Fabrication Technologies of the Sintered Materials Including Materials for Medical and Dental Application

“…A computer-controlled laser beam is guided across the powder surface with a CAD programme in successive layers (corresponding to the cross section of a virtual special model of an item recorded using CAD -D digital recording), causing the sintering of the powder particles in a strictly deined manner and in the selectively chosen places on the powder surface. A table with another layer of powder is lowered to the set height corresponding to one thickness of a layer resulting from the automatic virtual division of the spatial item model into layers with the set thickness, after each cycle corresponding to one scanning section of the powder bed and another, new layer of material is applied on the top [51,52,54,56,5 ]. The powder particle size range is between 20 and 0 μm, while the thickness of a single layer corresponds to approx.…”

“…It is important to align the element being produced relative to the working table, for example, the best accuracy of element diameter in diferent directions can be achieved by aligning a wheel in the XY plane level and then approx. 0.5 mm thick layers can be best produced by aligning them in the Z axis, while some parts can be achieved most advantageously in a plane oriented at the angle of 45° [54,58].…”

Fabrication, Structure, Properties and Application of Gradient Sintered Carbide-Steels with HS6-5-2 Matrix

“…In bone surgery, ceramic materials with a porosity gradient can be used for fabrication of orthopaedic gradients, which are designed just like a living bone tissue [65][66][67][68][69][70].…”

“…Bioactive hydroxyapatite is responsible for a strong connection with an organic tissue in such implants, whereas titanium is used in the parts of the implant requiring high mechanical stability. Gradient and porous materials are studied in the works [66][67][68][69][70], applied for implants, implant-scaffolds and scaffolds manufactured by selective laser sintering, what is detailed in the respective chapters of this book.…”

Powder Injection Moulding of Tool Materials and Materials Containing One-Dimensional Nanostructural Elements

“…This depends on the technological process applied, for example, hardfacing, thermal spraying, or selective laser sintering [1,2] exclude the need of powder forming. Powder forming itself does of this method's popularity, because it is employed for producing small elements.…”