X-Ray Microcomputed Tomography in Additive Manufacturing: A Review of the Current Technology and Applications

Plessis, Anton du; Yadroitsev, Igor; Yadroitsava, Ina; Roux, Stéphan

doi:10.1089/3dp.2018.0060

Cited by 377 publications

(176 citation statements)

References 94 publications

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“…Interestingly we found a complete absence of structural cavities in the conventionally manufactured cups. While these cavities are a known theoretical by‐product of the 3D printing process (du Plessis, Yadroitsev, Yadroitsava, & Le Roux, ; Sames et al, ), their prevalence in implants that are to be used in patients is noteworthy. However, no mechanical failures of 3D printed acetabular cups have been reported in literature, suggesting that these cavities do not affect their mechanical or clinical performance.…”

Section: Discussionmentioning

confidence: 99%

Evidence of structural cavities in 3D printed acetabular cups for total hip arthroplasty

et al. 2019

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The use of three-dimensional (3D) printing to manufacture off-the-shelf titanium acetabular cups for hip arthroplasty has increased; however, the impact of this manufacturing technology is yet not fully understood. Although several studies have described the presence of structural cavities in 3D printed parts, there has been no analysis of full postproduction acetabular components. The aim of this study was to investigate the effect of 3D printing on the material structure of acetabular implants, first comparing different designs of 3D printed cups, second comparing 3D printed with conventionally manufactured cups. Two of the 3D printed cups were produced using electron beam melting (EBM), one using laser rapid manufacturing (LRM). The investigation was performed using X-ray microcomputed tomography, imaging both the entire cups and samples sectioned from different regions of each cup. All 3D printed cups showed evidence of structural cavities; these were uniformly distributed in the volume of the samples and exhibited a prevalent spherical shape. The LRMmanufactured cup had significantly higher cavity density (p = .0286), with a median of 21 cavities/mm 3 compared to 3.5 cavities/mm 3 for EBM cups. However, the cavity size was similar, with a median of 20 μm (p = .7385). The conventional cups showed a complete absence of distinguishable cavities. The presence of cavities is a known limitation of the 3D printing technology; however, it is noteworthy that we found them in orthopedic implants used in patients. Although this may impact their mechanical properties, to date, 3D printed cups have not been reported to encounter such failures. K E Y W O R D S3D printing, acetabular cups, additive manufacturing, orthopedic implants, structural cavities

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Section: Discussionmentioning

confidence: 99%

Evidence of structural cavities in 3D printed acetabular cups for total hip arthroplasty

et al. 2019

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“…Moreover, it is essential that companies in this sector develop procedure guidelines, checklists, and powder traceability documentation for an appropriate powder lifecycle management and quality control . Furthermore, according to Du Plessis et al, a micro‐CT scanner is a key technology to control powder characteristics, since it is the only method that can determine the real sphericity, volume, and surface areas of powder particles to ensure flowability and eventually quality of the powder bed.…”

Section: Resultsmentioning

confidence: 99%

“…According to the interviewees' opinion, the most common preventive actions to reduce the probability of occurrence of these FMs are to provide adequate training for machine operators and the development of procedural guidelines for this process. One of the main technologies by the participating companies of this study is X‐ray Micro‐Computed Tomography scanner (micro‐CT) to identify trapped particles, presence of pores, internal flaws, and to perform dimensional validation of each implant . This type of industrial analysis using micro‐CT are described in detail by du Plessis et al…”

Section: Resultsmentioning

confidence: 99%

Quality by Design for industry translation: Three‐dimensional risk assessment failure mode, effects, and criticality analysis for additively manufactured patient‐specific implants

Martinez-Marquez

Terhaer

Scheinemann

et al. 2020

Engineering Reports

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The complexity of patient-specific implants combined with the current limited expertise in reliability engineering and manufacturability in the additive manufacturing (AM) sector is posing a number of quality performance challenges.Worldwide medical device regulatory bodies are facing increasing pressure to devise adequate standards to ensure long-term patient safety and product performance. The implementation of the Quality by Design (QbD) system to titanium 3D-printed bone implants offers a proven system to ensure that products are designed and manufactured correctly from the beginning without errors. This article reports on the development of a failure mode, effects, and criticality analysis (FMECA) coupled with a 3D risk assessment approach. This integrated approach is based on a questionnaire performed with three industry firms and three university research groups with significant experience and expertise in medical device product development and/or research in this field. Research outcomes include a FMECA form containing 137 failure modes with AM materials, AM machine general, fabrication, electron beam melting machine, finishing, and design being as the most sensitive process areas in terms of product quality. We subsequently propose corresponding preventive and corrective strategies for risk mitigation. The approach forms part of the QbD system being developed by the authors specifically for additive manufactured titanium patient-specific implants. K E Y W O R D Sadditive manufacturing, criticality analysis, failure mode effects, patient-specific implants, quality by designThis is an open access article under the terms of the Creative Commons Attribution License, which permits use, distribution and reproduction in any medium, provided the original work is properly cited.

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“…Several techniques can be used to assess these properties, such as geometrical measurements, liquid and powder immersion, mercury porosimetry, pycnometry, capillary flow porometry, fluid flow, gas sorption, calorimetric determination, microscopy (optical, SEM, TEM), and x-ray computed tomography (microCT) [95][96][97][98]. The applicability of these techniques will depend on the materials present, and the physical properties of the sample, such as surface characteristics, pore size range, and pore morphology.…”

Section: Characterization Of Porous Architecturesmentioning

confidence: 99%

“…The constant improvements in resolution and capabilities of microCT make it a powerful, nondestructive alternative to microscopy, that provides accurate data for dimensional measurement and porosity analysis throughout the entire structure [98]. However, the small sample sizes necessary to achieve high resolution mean that analysis is limited by the assumption that results would be similar in larger samples, and therefore it should always be done in combination with microscopy.…”

Section: Characterization Of Porous Architecturesmentioning

confidence: 99%

MXene-based 3D porous macrostructures for electrochemical energy storage

et al. 2020

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2D transition metal carbides and nitrides (MXenes) have shown outstanding potential as electrode materials for energy storage applications due to a combination of metallic conductivity, wide interlayer spacing, and redox-active, metal oxide-like surfaces capable of exhibiting pseudocapacitive behavior. It is well known that 2D materials have a strong tendency to restack and aggregate, due to their strong van der Waals interactions, reducing their surface availability and inhibiting electrochemical performance. In order to overcome these problems, work has been done to assemble 2D materials into 3D porous macrostructures. Structuring 2D materials in 3D can prevent agglomeration, increase specific surface area and improve ion diffusion, whilst also adding chemical and mechanical stability. Although still in its infancy, a number of papers already show the potential of 3D MXene architectures for energy storage, but the impact of the processing parameters on the microstructure of the materials, and the influence this has on electrochemical properties is still yet to be fully quantified. In some situations the reproducibility of works is hindered by an oversight of parameters which can, directly or indirectly, influence the final architecture and its properties. This review compiles publications from 2011 up to 2020 about the research developments in 3D porous macrostructures using MXenes as building blocks, and assesses their application as battery and supercapacitor electrodes. Recommendations are also made for future works to achieve a better understanding and progress in the field. carbon and/or nitrogen and T x represents surface terminations which vary depending on the synthesis method used (for example, hydroxyl, oxygen, or fluorine) [10].With less than 10 years since their discovery, efforts are still mainly pointed towards the assessment of its potentialities and exploration of its properties, while their integration and application in various engineering fields are still very much in their infancy. Nevertheless, investigations have shown very competitive results in energy storage devices attracting a lot of interest in the field. In particular, the inner conductive metal carbide layers provide fast electron supply to electrochemically active sites, and functional groups on the surface, allow water intercalation and fast redox activity for pseudocapacitive energy storage [11][12][13]. Besides energy storage, MXenes also showed promising properties and have been researched for a variety of other areas, such as electromagnetic shielding, environmental, sensors, optoeletronic devices, and renewable energy [9,[14][15][16].For most practical applications, the MXene powders must be assembled or processed into a macroscopic sample such as, for example, an electrode. Conventionally this is done either by mixing it with a solvent to form a slurry which is painted over a substrate, by directly vacuum filtration, by spin coating, or by spraying the MXene suspension to form a compact film. During these processes, there i...

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X-Ray Microcomputed Tomography in Additive Manufacturing: A Review of the Current Technology and Applications

Cited by 377 publications

References 94 publications

Evidence of structural cavities in 3D printed acetabular cups for total hip arthroplasty

Evidence of structural cavities in 3D printed acetabular cups for total hip arthroplasty

Quality by Design for industry translation: Three‐dimensional risk assessment failure mode, effects, and criticality analysis for additively manufactured patient‐specific implants

MXene-based 3D porous macrostructures for electrochemical energy storage

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