Design, optimization, and selective laser melting of vin tiles cellular structure-based hip implant

Abate, Kalayu Mekonen; Nazir, Aamer; Jeng, Jeng-Ywan

doi:10.1007/s00170-020-06323-5

Cited by 38 publications

(18 citation statements)

References 43 publications

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“…The advent of commercial metal additive manufacturing provides the opportunity to manufacture hip stems with intricate cellular geometries, resulting in stems that are less stiff than their solid counterparts [ 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 ]. Most have adopted a lattice size optimisation algorithm, which is inherently limited by a minimum feature size.…”

Section: Introductionmentioning

confidence: 99%

Topology Optimisation for Compliant Hip Implant Design and Reduced Strain Shielding

Tan

Arkel

2021

Materials

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Stiff total hip arthroplasty implants can lead to strain shielding, bone loss and complex revision surgery. The aim of this study was to develop topology optimisation techniques for more compliant hip implant design. The Solid Isotropic Material with Penalisation (SIMP) method was adapted, and two hip stems were designed and additive manufactured: (1) a stem based on a stochastic porous structure, and (2) a selectively hollowed approach. Finite element analyses and experimental measurements were conducted to measure stem stiffness and predict the reduction in stress shielding. The selectively hollowed implant increased peri-implanted femur surface strains by up to 25 percentage points compared to a solid implant without compromising predicted strength. Despite the stark differences in design, the experimentally measured stiffness results were near identical for the two optimised stems, with 39% and 40% reductions in the equivalent stiffness for the porous and selectively hollowed implants, respectively, compared to the solid implant. The selectively hollowed implant’s internal structure had a striking resemblance to the trabecular bone structures found in the femur, hinting at intrinsic congruency between nature’s design process and topology optimisation. The developed topology optimisation process enables compliant hip implant design for more natural load transfer, reduced strain shielding and improved implant survivorship.

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Section: Introductionmentioning

confidence: 99%

Topology Optimisation for Compliant Hip Implant Design and Reduced Strain Shielding

Tan

Arkel

2021

Materials

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“…The molds or died fabricated by the MAM technologies could also be employed for micro-injection molding, thermoforming, forging, hot embossing, blow molding, metal injection molding, die casting, hot extrusion, injectioncompression molding, rotational molding, thermoforming, transfer molding, or hot stamping. The microstructure of the injection mold manufactured by DMLS can be manipulated by laser power [41], hatch space [42], scanning speed, scanning strategy [43], or powder layer thickness. Normally, slower scanning speed, or higher laser power will contribute to grain size growth.…”

Section: Resultsmentioning

confidence: 99%

A low-cost and highly efficient method of reducing coolant leakage for direct metal printed injection mold with cooling channels using optimum heat treatment process procedures

Kuo

Qiu

Yang

2021

Int J Adv Manuf Technol

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Metal additive manufacturing (MAM) provides lots of bene ts and potentials in manufacturing molds or dies with sophisticated conformal cooling channels. It is known that the conformal cooling technology provides effective cooling to reduce cycle time for increasing productivity. Ordinarily, mold inserts fabricated by general printing procedures will result in coolant leakage in the injection molding process.The yield in the manufacturing of fully dense injection molding tools was limited to the very narrow working widow. In addition, high costs of fully dense injection mold fabricated by MAM constitute the major obstacle to its application in the mold or die industry. In general, the high cost of MAM is approximately 50-70% more expensive than conventional computer numerical control machining. In this study, a low-cost and highly e cient method of reducing coolant leakage for direct metal printed injection mold with cooling channels was proposed. This new method employs general process parameters to manufacture the green injection mold rapidly and then uses optimum heat treatment (HT) procedures to improve microstructure of the green injection mold. The results of this study revealed that optimum HT procedures can prevent coolant leakage and save manufacturing time of the injection mold fabricated by direct metal laser sintering. The evolution mechanisms of microstructure were investigated experimentally. The save in the injection mold manufacture time about 67% can be obtained.

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“… Femoral stem with regular porous structure. (A) 2D femoral stem using square unit cells designed by Arabnejad Khanoki and Pasini (2013) ; (B) femoral stem using BCC unit cells designed by Mehboob et al (2018) (C) femoral stem using tetrahedral topology designed by Wang et al (2018) ; (D) Stem using diamond lattice unit cells designed by Jette et al (2018) ; (E) Stem using Rhombic dodecahedron unit cells designed by Harrysson et al (2008) (F) Stem using vintile lattice unit cells by Abate et al; ( Abate et al, 2019 ; Abate et al, 2021 ); (G) Meta stem designed by Kolken et al (2018) , with the lateral part of the femoral stem having a re-entrant honeycomb structure and the medial part having a honeycomb structure. …”

Section: Porous Structures Applied To the Femoral Stemmentioning

confidence: 99%

“…This allows for fewer stress concentrations while maintaining excellent structural strength. Abate et al designed a porous femoral stem using a vintile lattice with porosity ranging from 41 to 71% ( Figures 3–F ) ( Abate et al, 2021 ). Using mechanical tests and finite element analysis, Abate et al found that porosities of 56 and 58% resulted in a stiffness of 1.581 and 1.252GPa, respectively, and compressive strength of 5.021 and 4.688GPa, respectively, which is close to that of human bone.…”

Section: Porous Structures Applied To the Femoral Stemmentioning

confidence: 99%

Femoral Stems With Porous Lattice Structures: A Review

Liu

Wang

Zhang

et al. 2021

Front. Bioeng. Biotechnol.

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Cementless femoral stems are prone to stress shielding of the femoral bone, which is caused by a mismatch in stiffness between the femoral stem and femur. This can cause bone resorption and resultant loosening of the implant. It is possible to reduce the stress shielding by using a femoral stem with porous structures and lower stiffness. A porous structure also provides a secondary function of allowing bone ingrowth, thus improving the long-term stability of the prosthesis. Furthermore, due to the advent of additive manufacturing (AM) technology, it is possible to fabricate femoral stems with internal porous lattices. Several review articles have discussed porous structures, mainly focusing on the geometric design, mechanical properties and influence on bone ingrowth. However, the safety and effectiveness of porous femoral stems depend not only on the characteristic of porous structure but also on the macro design of the femoral stem; for example, the distribution of the porous structure, the stem geometric shape, the material, and the manufacturing process. This review focuses on porous femoral stems, including the porous structure, macro geometric design of the stem, performance evaluation, research methods used for designing and evaluating the femoral stems, materials and manufacturing techniques. In addition, this review will evaluate whether porous femoral stems can reduce stress shielding and increase bone ingrowth, in addition to analyzing their shortcomings and related risks and providing ideas for potential design improvements.

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Design, optimization, and selective laser melting of vin tiles cellular structure-based hip implant

Cited by 38 publications

References 43 publications

Topology Optimisation for Compliant Hip Implant Design and Reduced Strain Shielding

Topology Optimisation for Compliant Hip Implant Design and Reduced Strain Shielding

A low-cost and highly efficient method of reducing coolant leakage for direct metal printed injection mold with cooling channels using optimum heat treatment process procedures

Femoral Stems With Porous Lattice Structures: A Review

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