Recent advancements in additive manufacturing technologies for porous material applications

Guddati, Subhash; Kiran, Ali S.; Leavy, Montray; Ramakrishna, Seeram

doi:10.1007/s00170-019-04116-z

Cited by 71 publications

(67 citation statements)

References 115 publications

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“…Another strategy is the introduction of porous structures, which has demonstrated promising results in increasing the osteogenic potential of PEEK [38][39][40]. The methods of fabricating three-dimensional (3D) porous structures are limited in conventional manufacturing technologies, and therefore, the clinical interest in additive manufacturing (AM) or 3D printing has rapidly grown [35,38,41,42].…”

Section: Introductionmentioning

confidence: 99%

“…The characteristics of a porous implant are crucially dependent on its structure, which can significantly impact the mechanical response, defining its clinical applicability. Additionally, the design freedom capabilities of computer-aided design modeling and 3D printing significantly increase the possible combinations for an implant, resulting in various treatment choices for a specific case [42]. The design of porous constructs and implant thicknesses can thus affect the performance of orbital mesh implants.…”

Section: Introductionmentioning

confidence: 99%

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A Multi-Criteria Assessment Strategy for 3D Printed Porous Polyetheretherketone (PEEK) Patient-Specific Implants for Orbital Wall Reconstruction

Sharma

Welker

Aghlmandi

et al. 2021

JCM

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Pure orbital blowout fractures occur within the confines of the internal orbital wall. Restoration of orbital form and volume is paramount to prevent functional and esthetic impairment. The anatomical peculiarity of the orbit has encouraged surgeons to develop implants with customized features to restore its architecture. This has resulted in worldwide clinical demand for patient-specific implants (PSIs) designed to fit precisely in the patient’s unique anatomy. Material extrusion or Fused filament fabrication (FFF) three-dimensional (3D) printing technology has enabled the fabrication of implant-grade polymers such as Polyetheretherketone (PEEK), paving the way for a more sophisticated generation of biomaterials. This study evaluates the FFF 3D printed PEEK orbital mesh customized implants with a metric considering the relevant design, biomechanical, and morphological parameters. The performance of the implants is studied as a function of varying thicknesses and porous design constructs through a finite element (FE) based computational model and a decision matrix based statistical approach. The maximum stress values achieved in our results predict the high durability of the implants, and the maximum deformation values were under one-tenth of a millimeter (mm) domain in all the implant profile configurations. The circular patterned implant (0.9 mm) had the best performance score. The study demonstrates that compounding multi-design computational analysis with 3D printing can be beneficial for the optimal restoration of the orbital floor.

show abstract

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Multi-Criteria Assessment Strategy for 3D Printed Porous Polyetheretherketone (PEEK) Patient-Specific Implants for Orbital Wall Reconstruction

Sharma

Welker

Aghlmandi

et al. 2021

JCM

View full text Add to dashboard Cite

show abstract

“…Porosity is an important subject in the additive manufacturing (AM) research field. Desired or engineered porosity is utilized nowadays for the production of bio-compatible metal implants and prostheses [1,2], bio-active ceramic scaffolds [3,4], geopolymer filters for water treatments [5], breathable steel for molding components [6], and multiple other applications [7]. The intrinsic design freedom of the additive process grants that the porosity can be engineered to a level of detail that is governed by the accuracy and precision of the process itself [8].…”

Section: Introductionmentioning

confidence: 99%

A Micro-Computed Tomography Comparison of the Porosity in Additively Fabricated CuCr1 Alloy Parts Using Virgin and Surface-Modified Powders

et al. 2021

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Recently, the use of novel CuCr1 surface-modified powder for reliable laser powder-bed fusion (LPBF) manufacturing has been proposed, enabling a broader LPBF processing window and longer powder storage life. Nevertheless, virgin CuCr1 powder is also LPBF processable, on the condition that a high-energy density is employed. In this work, we compare two dense specimens produced from virgin and surface-modified CuCr1 powder. Furthermore, a third sample fabricated from surface-modified powder is characterized to understand an abnormal porosity content initially detected through Archimedes testing. Utilizing high-resolution micro-CT scans, the nature of the defects present in the different samples is revealed. Pores are analyzed in terms of size, morphology and spatial distribution. The micro-CT data reveal that the virgin CuCr1 dense specimen displays keyhole pores plus pit cavities spanning multiple layer thicknesses. On the other hand, the sample fabricated with the surface-modified CuCr1 powder mainly contains small and spherical equi-distributed metallurgical defects. Finally, the CT analysis of the third specimen reveals the presence of a W contamination, favoring lack-of-fusion pores between subsequent LPBF layers. The LPBF melting mode (keyhole or conductive), the properties of the material, and the potential presence of contaminants are connected to the different porosity types and discussed.

show abstract

“…Another strategy is the introduction of porous structures, which has demonstrated promising results in increasing the osteogenic potential of PEEK [27][28][29]. The methods of fabricating three-dimensional (3D) porous structures are limited in conventional manufacturing technologies, and therefore, the clinical interest in additive manufacturing (AM) or 3D printing has rapidly grown [24,27,30,31].…”

Section: Introductionmentioning

confidence: 99%

“…The characteristics of a porous implant are crucially dependent on its structure, which can significantly impact the mechanical response, defining its clinical applicability. Additionally, the design freedom capabilities of computer-aided design (CAD) and 3D printing significantly increase the possible combinations for an implant, resulting in various treatment choices for a specific case [31]. The design of porous constructs and implant thicknesses can thus affect the performance of orbital mesh implants.…”

Section: Introductionmentioning

confidence: 99%

A Multi-Criteria Assessment Strategy for 3d Printed Porous Polyetheretherketone (Peek) Patient-Specific Implants for Orbital Wall Reconstruction

Sharma

Welker

Aghlmandi

et al. 2021

Preprint

View full text Add to dashboard Cite

Pure orbital blowout fractures occur within the confines of the internal orbital wall. Restoration of orbital form and volume is paramount to prevent functional and esthetic impairment. The anatomical peculiarity of the orbit has encouraged surgeons to develop implants with customized features to restore its architecture. This has resulted in worldwide clinical demand for patient-specific implants (PSIs) designed to fit precisely in the patient's unique anatomy. Fused filament fabrication (FFF) three-dimensional (3D) printing technology has enabled the fabrication of implant-grade polymers such as Polyetheretherketone (PEEK), paving the way for a more sophisticated generation of biomaterials. This study evaluates the FFF 3D printed PEEK orbital mesh customized implants with a metric considering the relevant design, biomechanical, and morphological parameters. The performance of the implants is studied as a function of varying thicknesses and porous design constructs through a finite element (FE) based computational model and a decision matrix based statistical approach. The maximum stress values achieved in our results predict the high durability of the implants, and the maximum deformation values were under one-tenth of a millimeter (mm) domain in all the implant profile configurations. The circular patterned implant (0.9 mm) had the best performance score. The study demonstrates that compounding multi-design computational analysis with 3D printing can be beneficial for the optimal restoration of the orbital floor.

show abstract

Recent advancements in additive manufacturing technologies for porous material applications

Cited by 71 publications

References 115 publications

A Multi-Criteria Assessment Strategy for 3D Printed Porous Polyetheretherketone (PEEK) Patient-Specific Implants for Orbital Wall Reconstruction

A Multi-Criteria Assessment Strategy for 3D Printed Porous Polyetheretherketone (PEEK) Patient-Specific Implants for Orbital Wall Reconstruction

A Micro-Computed Tomography Comparison of the Porosity in Additively Fabricated CuCr1 Alloy Parts Using Virgin and Surface-Modified Powders

A Multi-Criteria Assessment Strategy for 3d Printed Porous Polyetheretherketone (Peek) Patient-Specific Implants for Orbital Wall Reconstruction

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