Study on the designing rules and processability of porous structure based on selective laser melting (SLM)

Wang, Di; Yang, Yongqiang; Liu, Ruicheng; Xiao, Dongming; Sun, Jianfeng

doi:10.1016/j.jmatprotec.2013.05.001

Cited by 193 publications

(74 citation statements)

References 15 publications

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“…These deviations are as expected since the as-fabricated strut diameters were larger than the original designs, resulting in smaller pore sizes than the intended geometry. This difference is characteristic to SLM process and is caused by effects such as staircase stepping due to layered manufacturing and melt pool variation due to residual stresses [48].…”

Section: Mechanical Properties Of Porous Scaffoldsmentioning

confidence: 99%

Mechanical Properties and In Vitro Behavior of Additively Manufactured and Functionally Graded Ti6Al4V Porous Scaffolds

Onal

Frith

Jurg

et al. 2018

Metals

127

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Abstract:Functionally graded lattice structures produced by additive manufacturing are promising for bone tissue engineering. Spatial variations in their porosity are reported to vary the stiffness and make it comparable to cortical or trabecular bone. However, the interplay between the mechanical properties and biological response of functionally graded lattices is less clear. Here we show that by designing continuous gradient structures and studying their mechanical and biological properties simultaneously, orthopedic implant design can be improved and guidelines can be established. Our continuous gradient structures were generated by gradually changing the strut diameter of a body centered cubic (BCC) unit cell. This approach enables a smooth transition between unit cell layers and minimizes the effect of stress discontinuity within the scaffold. Scaffolds were fabricated using selective laser melting (SLM) and underwent mechanical and in vitro biological testing. Our results indicate that optimal gradient structures should possess small pores in their core (~900 µm) to increase their mechanical strength whilst large pores (~1100 µm) should be utilized in their outer surface to enhance cell penetration and proliferation. We suggest this approach could be widely used in the design of orthopedic implants to maximize both the mechanical and biological properties of the implant.

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Section: Mechanical Properties Of Porous Scaffoldsmentioning

confidence: 99%

Mechanical Properties and In Vitro Behavior of Additively Manufactured and Functionally Graded Ti6Al4V Porous Scaffolds

Onal

Frith

Jurg

et al. 2018

Metals

127

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“…Layer wise build up leads to larger overhanging layer sections with rising angular alignments resulting in an increase in powder adhesion due to a meltpool larger than one layer thickness. 29 In terms of buildability, support structures are necessary at angular alignments above b ¼ 80…”

Section: B Surface Qualitymentioning

confidence: 99%

Design guidelines for laser additive manufacturing of lightweight structures in TiAl6V4

Kranz

Herzog

Emmelmann

2014

Journal of Laser Applications

391

157

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Today, laser additive manufacturing (LAM) is used in more and more industrial applications. Due to a new freedom in design it offers a high potential for weight saving in lightweight applications, e.g., in the aerospace industry. However, most design engineers are used to design parts for conventional manufacturing methods, such as milling and casting, and often only have limited experience in designing products for additive manufacturing. The absence of comprehensive design guidelines is therefore limiting the further usage and distribution of LAM. In this paper, experimental investigations on the influence of part position and orientation on the dimension accuracy and surface quality are presented. Typical basic shapes used in lightweight design have been identified and built in LAM. Thin walls, bars, and bore holes with varying diameters were built in different orientations to determine the process limits. From the results of the experiments, comprehensive design guidelines for lightweight structures were derived in a catalog according to DIN 2222 and are presented in detail. For each structure a favorable and an unfavorable example is shown, the underlying process restrictions are mentioned and further recommendations are given.

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“…Tym razem zauważalny jest wyraźny spadek średnich pól i objętości wzniesień i dolin wraz ze wzrostem objętościowej gęstości energii. Parametry te osiągają lokalne minimum przy wartości ε=85 J/mm 3 . Dalszy wzrost dostarczanej za pomocą wiązki lasera energii nie powoduje zmniejszenia mikroobiętości powstałych wzniesień i dolin.…”

Section: Opracowanie Wyników Badańunclassified

Identification of parameters of selective laser melting process of the CoCr alloy on the basis of assorted parameters of topography of a surface after milling

Grzesiak

Grochała

2015

Mechanik

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Artykuł prezentuje przebieg i wyniki badań nad określeniem zależności pomiędzy parametrami procesu selektywnego stapiania laserowego SLM (selective laser melting) stopu CoCr a wybranymi parametrami topografii powierzchni po frezowaniu. Stop CoCr jest materiałem szeroko wykorzystywanym w medycynie, a zwłaszcza w dentystyce i protetyce. Jest powszechnie stosowany w technologiach przyrostowych, takich jak selektywne stapianie laserowe, i pozwala na wytwarzanie elementów o niemal dowolnie złożonej geometrii. Powstałe w ten sposób np. implanty można w bardzo wysokim stopniu spersonalizować. Ważnym aspektem jes również brak konieczności stosowania dodatkowego oprzyrządowania technologicznego, które znacznie podwyższa koszt produkcji jednostkowej, jaką jest wytwarzanie spersonalizowanych implantów medycznych. Jedną z największych wad technologii SLM jest wysoka chropowatość surowej powierzchni oraz niedostateczna dokładność wymiarowo-kształtowa. Pomimo że nad poprawą tych parametrów prowadzone są obecnie intensywne badania, a ich efekty są coraz lepsze, to zazwyczaj w celu uzyskania w pełni funkcjonalnych implantów zachodzi konieczność wykorzystania obróbki skrawaniem. Wcześniejsze badania pokazały, że w zależności od parametrów procesu SLM przedmioty wytworzone ze stopu CoCr mogą mieć zróżnico-wane właściwości mechaniczne. Różnice te są widoczne zwłaszcza podczas obróbki skrawaniem. Prezentowane w artykule wyniki badań mają dać odpowiedź na pytanie, w jaki sposób dobór parametrów procesu SLM może wpływać na topografię powierzchni otrzymaną po procesie frezowania. Słowa kluczowe: selektywne spiekanie laserowe, frezowanie IDENTIFICATION OF PARAMETERS OF SELECTIVE LASER MELTING PROCESS OF THE CoCr ALLOY ON THE BASIS OF ASSORTED PARAMETERS OF TOPOGRAPHY OF A SURFACE AFTER MILLING AbstractThe article presents the course and results of a study intended to determine the correlation between the parameters of the process of selective laser melting (SLM) of the CoCr alloy and assorted parameters of topography of a surface after milling. The CoCr alloy is a material widely used in medicine, particularly in dentistry and prosthetics. It is universally used in incremental technologies, such as selective laser melting, and allows manufacturing of elements with almost any complex geometries. Products made in such a manner, e.g. implants, enable a very large degree of customization. Another important aspect is the lack of necessity to use additional technological accessories significantly increasing the cost of unit production which is manufacturing of customized medical implants. One of the greatest disadvantages of the SLM technology is high roughness of the raw surface and insufficient dimensional and form accuracy. Although intense research is currently conducted in order to improve these parameters, and the effects thereof are increasingly better, there is usually a necessity to apply machining in order to obtain fully functional implants. The previous research has demonstrated that depending on the parameters of the SLM process...

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Study on the designing rules and processability of porous structure based on selective laser melting (SLM)

Cited by 193 publications

References 15 publications

Mechanical Properties and In Vitro Behavior of Additively Manufactured and Functionally Graded Ti6Al4V Porous Scaffolds

Mechanical Properties and In Vitro Behavior of Additively Manufactured and Functionally Graded Ti6Al4V Porous Scaffolds

Design guidelines for laser additive manufacturing of lightweight structures in TiAl6V4

Identification of parameters of selective laser melting process of the CoCr alloy on the basis of assorted parameters of topography of a surface after milling

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