Mechanical and morphological properties of additively manufactured SS316L and Ti6Al4V micro-struts as a function of build angle

Hossain, Umar; Ghouse, Shaaz; Nai, Kenneth; Jeffers, Jonathan R.T.

doi:10.1016/j.addma.2021.102050

Cited by 17 publications

(26 citation statements)

References 51 publications

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“…As the gyroid structure may be the most similar to cancellous bone, other lattice structures, with similar micro‐structure to gyroid, should be tested to further fine‐tune this model. Previous studies have demonstrated that lattice structures can be individually altered to change the material properties in different planes and orientations 93–95 . These methods can be applied to the present model to further fine‐tune the properties.…”

Section: Discussionmentioning

confidence: 99%

“…Previous studies have demonstrated that lattice structures can be individually altered to change the material properties in different planes and orientations. 93 , 94 , 95 These methods can be applied to the present model to further fine‐tune the properties. Finally, the overall structural strength of the model should be validated against cadaveric cervical spine specimen.…”

Section: Discussionmentioning

confidence: 99%

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An additively manufactured model for preclinical testing of cervical devices

Wahbeh,

Hookasian,

Lama

et al. 2023

JOR Spine

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PurposeComposite models have become commonplace for the assessment of fixation and stability of total joint replacements; however, there are no comparable models for the cervical spine to evaluate fixation. The goal of this study was to create the framework for a tunable non‐homogeneous model of cervical vertebral body by identifying the relationships between strength, in‐fill density, and lattice structure and creating a final architectural framework for specific strengths to be applied to the model.MethodsThe range of material properties for cervical spine were identified from literature. Using additive manufacturing software, rectangular prints with three lattice structures, gyroid, triangle, zig‐zag, and a range of in‐fill densities were 3D‐printed. The compressive and shear strengths for all combinations were calculated in the axial and coronal planes. Eleven unique vertebral regions were selected to represent the distribution of density. Each bone density was converted to strength and subsequently correlated to the lattice structure and in‐fill density with the desired material properties. Finally, a complete cervical vertebra model was 3D‐printed to ensure sufficient print quality.ResultsMaterials testing identified a relationship between in‐fill densities and strength for all lattice structures. The axial compressive strength of the gyroid specimens ranged from 1.5 MPa at 10% infill to 31.3 MPa at 100% infill and the triangle structure ranged from 2.7 MPa at 10% infill to 58.4 MPa at 100% infill. Based on these results, a cervical vertebra model was created utilizing cervical cancellous strength values and the corresponding in‐fill density and lattice structure combination. This model was then printed with 11 different in‐fill densities ranging from 33% gyroid to 84% triangle to ensure successful integration of the non‐homogeneous in‐fill densities and lattice structures.ConclusionsThe findings from this study introduced a framework for using additive manufacturing to create a tunable, customizable biomimetic model of a cervical vertebra.

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Section: Discussionmentioning

confidence: 99%

Section: Discussionmentioning

confidence: 99%

An additively manufactured model for preclinical testing of cervical devices

Wahbeh,

Hookasian,

Lama

et al. 2023

JOR Spine

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“…To avoid the need for supports for the lattice structure, which would result difficult to be removed, the lattice structures could be angled for production, but it is not possible to define an ideal printing orientation due to the variable orientation of the conformal lattice. Nevertheless, recent studies have shown that small sizes of the beam may not require the use of supports [82,83], so considering the size of the beams of the studied lattice structures, it might be possible to produce them vertically by SLM technologies.…”

Section: Structural Analysis Validationmentioning

confidence: 99%

Analysis of a Preliminary Design Approach for Conformal Lattice Structures

et al. 2021

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An important issue when designing conformal lattice structures is the geometric modeling and prediction of mechanical properties. This paper presents suitable methods for obtaining optimized conformal lattice structures and validating them without the need for high computational power and time, enabling the designer to have quick feedback in the first design phases. A wireframe modeling method based on non-uniform rational basis spline (NURBS) free-form deformation (FFD) that allows conforming a regular lattice structure inside a design space is presented. Next, a previously proposed size optimization method is adopted for optimizing the cross-sections of lattice structures. Finally, two different commercial finite element software are involved for the validation of the results, based on Euler–Bernoulli and Timoshenko beam theories. The findings highlight the adaptability of the NURBS-FFD modeling approach and the reliability of the size optimization method, especially in stretching-dominated cell topologies and load conditions. At the same time, the limitation of the structural beam analysis when dealing with thick beams is noted. Moreover, the behavior of different kinds of lattices was investigated.

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“…SS316L has been commonly used in a wide range of industrial applications considering its high strength, high oxidation and corrosion resistance and good heat resistance (Bautista et al , 2003; Choi et al , 2015; Simchi et al , 2006). Generally, SS316L has been fabricated by BJT for applications such as electrochemical or bio-medical (Gokuldoss et al , 2017) or depending upon the application; it can also be fabricated using BJT (Frykholm et al , 2016) or LPBF (Hossain et al , 2021; Lin et al , 2020; Alharbi, 2022).…”

Section: Introductionmentioning

confidence: 99%

Binder jetting of SS316L: a computational approach for droplet-powder interaction

Rehman

Azher

Ullah

et al. 2023

RPJ

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Purpose This study aims to describe the effects of capillary forces or action, viscosity, gravity and inertia via the computational fluid dynamics (CFD) analysis. The study also includes distribution of the binder droplet over the powder bed after interacting from different heights. Design/methodology/approach Additive manufacturing (AM) has revolutionized many industries. Binder jetting (BJT) is a powder-based AM method that enables the production of complex components for a wide range of applications. The pre-densification interaction of binder and powder is vital among various parameters that can affect the BJT performance. In this study, BJT process is studied for the binder interaction with the powder bed of SS316L. The effect of the droplet-powder distance is thoroughly analysed. Two different droplet heights are considered, namely, h1 (zero) and h2 (9.89 mm). Findings The capillary and inertial effects are predominant, as the distance affects these parameters significantly. The binder spreading and penetration depth onto the powder bed is influenced directly by the distance of the binder droplet. The former increases with an increase in latter. The binder distribution over the powder bed, whether uniform or not, is studied by the stream traces. The penetration depth of the binder was also observed along the cross-section of the powder bed through the same. Originality/value In this work, the authors have developed a more accurate representative discrete element method of the powder bed and CFD analysis of binder droplet spreading and penetration inside the powder bed using Flow-3D. Moreover, the importance of the splashing due to the binder’s droplet height is observed. If splashing occurs, it will produce distortion in the powder, resulting in a void in the final part.

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Mechanical and morphological properties of additively manufactured SS316L and Ti6Al4V micro-struts as a function of build angle

Cited by 17 publications

References 51 publications

An additively manufactured model for preclinical testing of cervical devices

An additively manufactured model for preclinical testing of cervical devices

Analysis of a Preliminary Design Approach for Conformal Lattice Structures

Binder jetting of SS316L: a computational approach for droplet-powder interaction

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