Development of Craniofacial Implants Produced by Metal Injection Molding of Titanium Alloy Using Novel Binder System Based on Palm Oil

Abstract

Metal Injection Molding (MIM) is a cost-effective technique for producing small, complex, precision parts in high volumes. MIM consists of four main processing steps: mixing, injection molding, debinding and sintering. In the mixing step, the powder titanium alloy (Ti6Al4V) medical grade is mixed with a binder system based on palm stearin to form a homogeneous feedstock. The rheological studies of the feedstock have been determined properly in order to success during injection into injection molding machine. After molding, the binder holds the particles in place. The binder systems then have to be removed completely through debinding step. Any contamination of the binder systems will affect the final properties of the parts. During debinding step, solvent extraction debinding has been used to remove partly of the binder systems. The debound part is then sintered at high temperature under control atmosphere furnace. The properties of the sintered craniofacial implants then was measured and compared. The sintered craniofacial implants also then were determined in term of in-vitro cytotoxicity study using mouse fibroblast lines L-929. The results show that the sintered craniofacial implants of titanium alloy produced by MIM fullfill the in-vitro cytotoxicity test.

Biocompatibility of Advanced Manufactured Titanium Implants—A Review

“…Yet more studies relating to the study of the biocompatibility of MIM Ti-64 were carried out by Ibrahim et al [ 46 ]. Firstly, the in vitro cytotoxicity of MIM Ti-64 was carried out using the mouse fibroblast L929 cell lines.…”

“…The MIM Ti-64 part was found to be non-toxic to mouse fibroblast cell lines L929. Most of the cells proliferated with numerous filopodia and were attached to the MIM Ti-64 part [ 46 ]. Secondly, Ibrahim et al [ 46 ] carried out an in vivo test of the MIM Ti-64 by placing the implant into the mandible of Macaca fascicularis.…”

“…Most of the cells proliferated with numerous filopodia and were attached to the MIM Ti-64 part [ 46 ]. Secondly, Ibrahim et al [ 46 ] carried out an in vivo test of the MIM Ti-64 by placing the implant into the mandible of Macaca fascicularis. Results showed continuous contact between surrounding tissue and the Ti-64 implant as shown in Figure 7 [ 46 ].…”

Metal Injection Molding of Low Alloy Steel by Using a Palm Stearin/HDPE Binder System

“…Moreover, PS can be dissolved easily in heptane. In addition, according to different studies, using PS results in a lower amount of contaminations with carbon, nitrogen, and oxygen because this contamination for many metals leads to serious problems in sintering and reduce the final properties [5,[22][23][24]. The impact of PS on the rheological behavior of 316L stainless steel was investigated by Omar et al [24].…”

Physical and Mechanical Properties of Injection Molded Co-Cr-Mo Alloy Powder for Orthopedic Applications

“…The MIM procedure created from the conventional shape-production ability of plastic injection molding and the materials adaptability of powder metallurgy. The MIM procedure comprises of four principle steps: blending, injection molding, debinding and sintering [1]. In the blending step, the powder is blended with a typical binder volume percentage of 30-70%, to form a homogeneous feedstock.…”