Next Generation Orthopaedic Implants by Additive Manufacturing Using Electron Beam Melting

Murr, L. E.; Gaytan, Sara M.; Martínez, E.; Medina, Frank; Wicker, Ryan B.

doi:10.1155/2012/245727

Cited by 257 publications

(143 citation statements)

References 23 publications

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“…A commonly used method to fabricate an implant with a porous structure on its surface is to apply a porous coating to the surface of the main body of the implant after initial manufacture. However, there are some concerns about these porous-coated implants; for example, cracking, detachment, and electrical incompatibility between the implant and the coated layer 1) . Ideally, the porous surface and the main body of the implant should be fabricated integrally as one piece.…”

Section: Introductionmentioning

confidence: 99%

Bioactive treatment promotes osteoblast differentiation on titanium materials fabricated by selective laser melting technology

Tsukanaka

Fujibayashi

Takemoto

et al. 2016

Dental Materials Journal

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Selective laser melting (SLM) technology is useful for the fabrication of porous titanium implants with complex shapes and structures. The materials fabricated by SLM characteristically have a very rough surface (average surface roughness, Ra=24.58 µm). In this study, we evaluated morphologically and biochemically the specific effects of this very rough surface and the additional effects of a bioactive treatment on osteoblast proliferation and differentiation. Flat-rolled titanium materials (Ra=1.02 µm) were used as the controls. On the treated materials fabricated by SLM, we observed enhanced osteoblast differentiation compared with the flat-rolled materials and the untreated materials fabricated by SLM. No significant differences were observed between the flat-rolled materials and the untreated materials fabricated by SLM in their effects on osteoblast differentiation. We concluded that the very rough surface fabricated by SLM had to undergo a bioactive treatment to obtain a positive effect on osteoblast differentiation.

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Section: Introductionmentioning

confidence: 99%

Bioactive treatment promotes osteoblast differentiation on titanium materials fabricated by selective laser melting technology

Tsukanaka

Fujibayashi

Takemoto

et al. 2016

Dental Materials Journal

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show abstract

“…Another approach is alloy design. In the last decade, with the advancement in manufacturing techniques, porous metal structures have been fabricated by additive manufacturing (AM) (layer-by-layer fabrication) from precursor powders using electron beam melting (EBM) and selective laser melting (SLM) [26][27][28]. The following sections summarize the advancements in design, structure, process, and properties of porous titanium alloy components fabricated by EBM for orthopedic applications.…”

Section: Evolution Of Additive Manufacturingmentioning

confidence: 99%

“…Thus, to obtain a replica of natural bone, 3D scaffolds with graded porosity were studied, since porosity is related to the elastic modulus according to Gibson-Ashby equation: E=E 0 (ρ/ρ 0 ) 2 [81]. In this regard, titanium alloy rod with graded density, characterized by a lower density inner foam (density~0.6 g cm −3 ; stiffness 0.3 GPa), surrounded by a foam with relatively higher density (~1.1 g cm −3 ; stiffness~2.2 GPa) was fabricated [28].…”

Section: Role Of Complex Design Architectures (Graded/gradient)mentioning

confidence: 99%

Advancements in three-dimensional titanium alloy mesh scaffolds fabricated by electron beam melting for biomedical devices: mechanical and biological aspects

Nune

Misra

2017

Sci. China Mater.

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We elucidate here the process-structure-property relationships in three-dimensional (3D) implantable titanium alloy biomaterials processed by electron beam melting (EBM) that is based on the principle of additive manufacturing. The conventional methods for processing of biomedical devices including freeze casting and sintering are limited because of the difficulties in adaptation at the host site and difference in the micro/macrostructure, mechanical, and physical properties with the host tissue. In this regard, EBM has a unique advantage of processing patient-specific complex designs, which can be either obtained from the computed tomography (CT) scan of the defect site or through a computeraided design (CAD) program. This review introduces and summarizes the evolution and underlying reasons that have motivated 3D printing of scaffolds for tissue regeneration. The overview comprises of two parts for obtaining ultimate functionalities. The first part focuses on obtaining the ultimate functionalities in terms of mechanical properties of 3D titanium alloy scaffolds fabricated by EBM with different characteristics based on design, unit cell, processing parameters, scan speed, porosity, and heat treatment. The second part focuses on the advancement of enhancing biological responses of these 3D scaffolds and the influence of surface modification on cell-material interactions. The overview concludes with a discussion on the clinical trials of these 3D porous scaffolds illustrating their potential in meeting the current needs of the biomedical industry.

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“…Potential problems with the use of coatings to create surface roughness and porosity include coating delamination and cracking under fatigue (Murr et al, 2012), as well as a limit to the volume of porosity achieved by these methods (Bobyn et al, 1999). To overcome such issues, additive manufacture (AM) has become an area of growing interest for manufacturing parts with complex surface geometries.…”

Section: Introductionmentioning

confidence: 99%

Combining 3D human in vitro methods for a 3Rs evaluation of novel titanium surfaces in orthopaedic applications

Stevenson

Rehman

Draper

et al. 2016

Biotech & Bioengineering

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In this study, we report on a group of complementary human osteoblast in vitro test methods for the preclinical evaluation of 3D porous titanium surfaces. The surfaces were prepared by additive manufacturing (electron beam melting [EBM]) and plasma spraying, allowing the creation of complex lattice surface geometries. Physical properties of the surfaces were characterized by SEM and profilometry and 3D in vitro cell culture using human osteoblasts. Primary human osteoblast cells were found to elicit greater differences between titanium sample surfaces than an MG63 osteoblast‐like cell line, particularly in terms of cell survival. Surface morphology was associated with higher osteoblast metabolic activity and mineralization on rougher titanium plasma spray coated surfaces than smoother surfaces. Differences in osteoblast survival and metabolic activity on titanium lattice structures were also found, despite analogous surface morphology at the cellular level. 3D confocal microscopy identified osteoblast organization within complex titanium surface geometries, adhesion, spreading, and alignment to the biomaterial strut geometries. Mineralized nodule formation throughout the lattice structures was also observed, and indicative of early markers of bone in‐growth on such materials. Testing methods such as those presented are not traditionally considered by medical device manufacturers, but we suggest have value as an increasingly vital tool in efficiently translating pre‐clinical studies, especially in balance with current regulatory practice, commercial demands, the 3Rs, and the relative merits of in vitro and in vivo studies. Biotechnol. Bioeng. 2016;113: 1586–1599. © 2015 The Authors. Biotechnology and Bioengineering Published by Wiley Periodicals, Inc.

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Next Generation Orthopaedic Implants by Additive Manufacturing Using Electron Beam Melting

Cited by 257 publications

References 23 publications

Bioactive treatment promotes osteoblast differentiation on titanium materials fabricated by selective laser melting technology

Bioactive treatment promotes osteoblast differentiation on titanium materials fabricated by selective laser melting technology

Advancements in three-dimensional titanium alloy mesh scaffolds fabricated by electron beam melting for biomedical devices: mechanical and biological aspects

Combining 3D human in vitro methods for a 3Rs evaluation of novel titanium surfaces in orthopaedic applications

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