Open Journal Systems





Producing hip implants of titanium alloys by additive manufacturing

VIEWS - 1169 (Abstract) 835 (PDF)
Anatoliy Popovich, Vadim Sufiiarov, Igor Polozov, Evgenii Borisov, Dmitriy Masaylo

Abstract


Additive manufacturing (AM) technologies, in particular selective laser melting (SLM) allows the production of complex-shaped individual implants from titanium alloys with high biocompatibility, mechanical properties, and improved osseointegration by surface texturing. In this work, the possibility of producing a custom-made hip implant from Ti-6Al-4V powder according to the data acquired via computed tomography of the patient is shown. Different heat treatments were applied in order to achieve better combination of tensile strength and elongation by partial decomposition of the martensitic phase. The implant was installed to the patient, postoperative supervision has shown good results, and the patient is able to move with the installed implant. A successful case of applying AM for producing custom hip implant is demonstrated in the paper. Using AM allowed the production of a custom-made hip implant in a short time and decreases the operation time and lessens the risk of infection ingress.


Keywords


selective laser melting; implant; Ti-6Al-4V; biomedical application; prosthesis

Full Text:

PDF

References


An J, Chua C K and Mironov V, 2016, A perspective on 4D bioprinting. International Journal of Bioprinting, vol.2(1): 3–5. http://dx.doi.org/10.18063/IJB.2016.01.003

Doubrovski Z, Verlinden J C and Geraedts J M, 2011, Optimal design for additive manufacturing: Opportunities and challenges. Volume 9: 23rd International Conference on Design Theory and Methodology; 16th Design for Manufacturing and the Life Cycle Conference, August 28–31, 2001, 635–646. Washington, DC, USA. http://dx.doi.org/10.1115/detc2011-48131

Gao W, Zhang Y, Ramanujan D, et al., 2015, The status, challenges, and future of additive manufacturing in engineering. Computer-Aided Design, vol.69: 65–89. http://dx.doi.org/10.1016/j.cad.2015.04.001

Uhlmann E, Kersting R, Klein T B, et al., 2015, Additive manufacturing of titanium alloy for aircraft components. Procedia CIRP, vol.35: 55–60. http://dx.doi.org/10.1016/j.procir.2015.08.061

Vandenbroucke B and Kruth J P, 2007, Selective laser melting of biocompatible metals for rapid manufacturing of medical parts. Rapid Prototyping Journal, vol.13(4): 196–203. http://dx.doi.org/10.1108/13552540710776142

Sallica-Leva E, Caram R, Jardini A L, et al., 2016, Ductility improvement due to martensite α′decomposition in porous Ti–6Al–4V parts produced by selective laser melting for orthopedic implants. Journal of the Mechanical Behavior of Biomedical Materials, vol.54: 149–158. http://dx.doi.org/10.1016/j.jmbbm.2015.09.020

Mercelis P and Kruth J P, 2006, Residual stresses in selective laser sintering and selective laser melting. Rapid Prototyping Journal, vol.12(5): 254–265. http://dx.doi.org/10.1108/13552540610707013

Sames W J, List F A, Pannala S, et al., 2016, The metallurgy and processing science of metal additive manufacturing. International Materials Reviews, vol.6608: 1–46. http://dx.doi.org/10.1080/09506608.2015.1116649

Yadroitsev I, Krakhmalev P and Yadroitsava I, 2014, Selective laser melting of Ti6Al4V alloy for biomedical applications: temperature monitoring and microstructural evolution. Journal of Alloys and Compounds, vol.583: 404–409. http://dx.doi.org/10.1016/j.jallcom.2013.08.183

Popovich A A, Sufiiarov V S, Polozov I A, et al., 2015, Microstructure and mechanical properties of Inconel 718 produced by SLM and subsequent heat treatment. Key Engineering Materials, vol.651–653: 665–670. http://dx.doi.org/10.4028/www.scientific.net/KEM.651-653.665

Frazier W E, 2014, Metal additive manufacturing: A review. Journal of Materials Engineering and Performance, vol.23(6): 1917–1928. http://dx.doi.org/10.1007/s11665-014-0958-z

Kurtz S, Ong K, Lau E, et al., 2007, Projections of primary and revision hip and knee arthroplasty in the United States from 2005 to 2030. Journal of Bone and Joint Surgery. American Volume, vol.89(4): 780–785. http://dx.doi.org/10.2106/JBJS.F.00222

Pivec R, Johnson A J, Mears S C, et al., 2012, Hip arthroplasty. Lancet, vol.380(9855): 1768–1777. http://dx.doi.org/10.1016/S0140-6736(12)60607-2

Herberts P and Malchau H, 2000, Long-term registration has improved the quality of hip replacement: A review of the Swedish THR register comparing 160,000 cases. Acta Orthopaedica Scandinavica, vol.71(2): 111–121. http://dx.doi.org/10.1080/000164700317413067

Deirmengian G K, Zmistowski B, O’Neil J T, et al., 2011, Management of acetabular bone loss in revision total hip arthroplasty. The Journal of Bone and Joint Surgery. American Volume, vol.93(19): 1842–1852. http://dx.doi.org/10.2106/JBJS.J.01197

Civinini R, Capone A, Carulli C, et al., 2008, Acetabular revisions using a cementless oblong cup: Five to ten year results. International Orthopaedics, vol.32(2): 189– 193. http://dx.doi.org/10.1007/s00264-006-0307-4

Issack P S, Nousiainen M, Beksac B, et al., 2009, Acetabular component revision in total hip arthroplasty. Part I: Cementless shells. American Journal of Orthopedics (Belle Mead NJ), vol.38(10): 509–514.

Lütjering G, Williams J C and Gysler A. 2000, Microstructure and mechanical properties of titanium alloys, in Microstructure and Properties of Materials vol.2, Li J C M (ed.), World Scientific Publishing Co. Pte. Ltd., Singapore, 49–55.

Sun J, Yang Y and Wang D, 2013, Mechanical properties of a Ti6Al4V porous structure produced by selective laser melting. Materials & Design, vol.49: 545– 552. http://dx.doi.org/10.1016/j.matdes.2013.01.038

Hallmann S, Glockner P, Daniel C, et al., 2015, Manufacturing of medical implants by combination of selective laser melting and laser ablation. Lasers in Manufacturing and Materials Processing, vol.2(3): 124–134. http://dx.doi.org/10.1007/s40516-015-0010-7

Harrysson O L A, Cansizoglu O, Marcellin-Little D J, et al., 2008, Direct metal fabrication of titanium implants with tailored materials and mechanical properties using electron beam melting technology. Materials Science and Engineering: C, vol.28(3): 366–373. http://dx.doi.org/10.1016/j.msec.2007.04.022

Cansizoglu O, Harrysson O, Cormier D, et al., 2008, Properties of Ti–6Al–4V non-stochastic lattice structures fabricated via electron beam melting. Materials Science and Engineering: A, 492(1–2): 468–474. http://dx.doi.org/10.1016/j.msea.2008.04.002

Sing S L, An J, Yeong W Y, et al., 2016, Laser and electron-beam powder-bed additive manufacturing of metallic implants: a review on processes, materials and designs. Journal of Orthopaedic Research, vol.34(3): 369–385. http://dx.doi.org/10.1002/jor.23075

Yap C Y, Chua C K, Dong Z L, et al., 2015, Review of selective laser melting: Materials and applications. Applied Physics Reviews, vol.2(4): 041101. http://dx.doi.org/10.1063/1.4935926

Sing S L, Yeong W Y and Wiria F E, 2016, Selective laser melting of titanium alloy with 50 wt% tantalum: Microstructure and mechanical properties. Journal of Al-loys and Compounds, vol.660, 461-470. http://dx.doi.org/10.1016/j.jallcom.2015.11.141

Popovich A, Sufiiarov V, Borisov E, et al., 2015, Microstructure and mechanical properties of Ti-6Al-4V manufactured by SLM. Key Engineering Materials, vol.651– 653: 677–682. http://dx.doi.org/10.4028/www.scientific.net/KEM.651-653.677

Sufiiarov V S, Popovich A A, Borisov E V, et al., 2015, Selective laser melting of titanium alloy and manufacturing of gas-turbine engine part blanks. Tsvetnye Metally, vol.8: 76–80. http://dx.doi.org/10.17580/tsm.2015.08.11

Warnke P H, Douglas T, Wollny P, et al., 2009, Rapid prototyping: Porous titanium alloy scaffolds produced by selective laser melting for bone tissue engineering. Tissue Engineering Part C: Methods, vol.15(2): 115–124. http://dx.doi.org/10.1089/ten.tec.2008.0288

Vrancken B, Thijs L, Kruth J P, et al., 2014, Microstructure and mechanical properties of a novel β titanium metallic composite by selective laser melting. Acta Materialia, vol.68: 150–158. http://dx.doi.org/10.1016/j.actamat.2014.01.018

Thijs L, Verhaeghe F, Craeghs T, et al., 2010, A study of the microstructural evolution during selective laser melting of Ti–6Al–4V. Acta Materialia, vol.58(9): 3303– 3312. http://dx.doi.org/10.1016/j.actamat.2010.02.004

Facchini L, Magalini E, Robotti P, et al., 2010, Ductility of a Ti-6Al-4V alloy produced by selective laser melting of prealloyed powders. Rapid Prototyping Journal, vol.16(6): 450–459. http://dx.doi.org/10.1108/13552541011083371

Liu F, Lin X, Yang G, et al., 2011, Microstructure and residual stress of laser rapid formed Inconel 718 nickel-base superalloy. Optics & Laser Technology, vol.43(1): 208–213. http://dx.doi.org/10.1016/j.optlastec.2010.06.015

Yadroitsev I and Yadroitsava I, 2015, Evaluation of residual stress in stainless steel 316L and Ti6Al4V samples produced by selective laser melting. Virtual and Physical Prototyping, vol.10(2): 67–76. http://dx.doi.org/10.1080/17452759.2015.1026045




DOI: http://dx.doi.org/10.18063/IJB.2016.02.004

Refbacks

  • There are currently no refbacks.


Copyright (c) 2017 Anatoliy Popovich, Vadim Sufiiarov, Igor Polozov, Evgenii Borisov, Dmitriy Masaylo

Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.