Trapped powder removal from sheet-based porous structures based on triply periodic minimal surfaces fabricated by electron beam powder bed fusion

Khrapov, Dmitriy; Paveleva, Aleksandra; Kozadayeva, Maria; Evsevleev, Sergei; Mishurova, Tatiana; Bruno, Giovanni; Surmenev, Roman A.; Koptyug, Andrey; Surmeneva, Maria A.

doi:10.1016/j.msea.2022.144479

Cited by 29 publications

(13 citation statements)

References 44 publications

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“…Appropriate methods should be implemented for the powder-bed fusion 3D printing of metals [86] as multi-scale, multi-physics phenomena occur that might lead to structural defects and implications if sub-optimal processing parameters are selected [27,87,88]. For example, the de-powdering of un-melted and trapped powder particles after the completion of laser-based powder-bed fusion 3D printing is critical, as there is a risk of particles entering the patient's body; air-jetting followed by dry ultrasonic vibration and/or chemical etching is important [89]. In addition, if the surface finish, dimensional accuracy, and fatigue properties have to be improved, post-processing methods such as machining and heat treatments can be applied.…”

Section: Resultsmentioning

confidence: 99%

Point-of-Care Orthopedic Oncology Device Development

Mavrodontis,

Trikoupis,

Kontogeorgakos

et al. 2023

Current Oncology

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Background: The triad of 3D design, 3D printing, and xReality technologies is explored and exploited to collaboratively realize patient-specific products in a timely manner with an emphasis on designs with meta-(bio)materials. Methods: A case study on pelvic reconstruction after oncological resection (osteosarcoma) was selected and conducted to evaluate the applicability and performance of an inter-epistemic workflow and the feasibility and potential of 3D technologies for modeling, optimizing, and materializing individualized orthopedic devices at the point of care (PoC). Results: Image-based diagnosis and treatment at the PoC can be readily deployed to develop orthopedic devices for pre-operative planning, training, intra-operative navigation, and bone substitution. Conclusions: Inter-epistemic symbiosis between orthopedic surgeons and (bio)mechanical engineers at the PoC, fostered by appropriate quality management systems and end-to-end workflows under suitable scientifically amalgamated synergies, could maximize the potential benefits. However, increased awareness is recommended to explore and exploit the full potential of 3D technologies at the PoC to deliver medical devices with greater customization, innovation in design, cost-effectiveness, and high quality.

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Section: Resultsmentioning

confidence: 99%

Point-of-Care Orthopedic Oncology Device Development

Mavrodontis,

Trikoupis,

Kontogeorgakos

et al. 2023

Current Oncology

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“…In addition, it was difficult to efficiently replace the solution that had already interacted with the scaffold. Ti64 particles were observed inside the scaffolds even after AE treatment for several minutes or tens of minutes, while the external unit cells of the scaffolds were overetched. , Dynamic acid etching also failed to achieve satisfactory internal and external consistency of acid-etching treatments . The FAE method successfully achieved consistent treatment of the external and internal surfaces of the scaffolds.…”

Section: Discussionmentioning

confidence: 99%

“…However, the removal of the Ti64 particles from the internal surface of the scaffolds was not further characterized. Khrapov et al 28 further analyzed the effects of graded acid etching on the topology of the scaffolds. The wall thickness of the scaffolds near the outside was significantly reduced, while no obvious change of the wall thickness was observed, but Ti64 particles were observed inside the scaffolds.…”

Section: Introductionmentioning

confidence: 99%

Complete Removal of Residual Particles and Realization of Mechanical Properties to Improve Osseointegration in Additively Manufactured Ti6Al4 V Scaffolds through Flowing Acid Etching

Wang,

Wan,

et al. 2024

ACS Biomater. Sci. Eng.

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Massive unmelted Ti6Al4 V (Ti64) particles presented across all surfaces of additively manufactured Ti64 scaffolds significantly impacted the designed surface topography, mechanical properties, and permeability, reducing the osseointegration of the scaffolds. In this study, the proposed flowing acid etching (FAE) method presented high efficiency in eliminating Ti64 particles and enhancing the surface modification capacity across all surfaces of Ti64 scaffolds. The Ti64 particles across all surfaces of the scaffolds were completely removed effectively and evenly. The surface topography of the scaffolds closely resembled the design after the 75 s FAE treatment. The actual elastic modulus of the treated scaffolds (3.206 ± 0.040 GPa) was closer to the designed value (3.110 GPa), and a micrometer-scale structure was constructed on the inner and outer surfaces of the scaffolds after the 90 s FAE treatment. However, the yield strength of scaffolds was reduced to 89.743 ± 0.893 MPa from 118.251 ± 0.982 MPa after the 90 s FAE treatment. The FAE method also showed higher efficiency in decreasing the roughness and enhancing the hydrophilicity and surface energy of all of the surfaces. The FAE treatment improved the permeability of scaffolds efficiently, and the permeability of scaffolds increased to 11.93 ± 0.21 × 10 −10 mm 2 from 8.57 ± 0.021 × 10 −10 mm 2 after the 90 s FAE treatment. The treated Ti64 scaffolds after the 90 s FAE treatment exhibited optimized osseointegration effects in vitro and in vivo. In conclusion, the FAE method was an efficient way to eliminate unmelted Ti64 particles and obtain ideal surface topography, mechanical properties, and permeability to promote osseointegration in additively manufactured Ti64 scaffolds.

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“…SLS process is one of the fusion technologies of the powder bed based on the principle of sintering of metal, powder and ceramic powders instead of melting using a focused laser beam (Węglowski, 2018;Nouri et al, 2021). Since it does not require any support structure compared to other powder bed processes, it is seen as an important advantage to fill the entire construction volume and make more production at one time (Khrapov et al, 2023). For thermoplastic materials, it is possible to produce quite good and long-lasting parts in terms of mechanical properties (Bijwe et al, 2000;Musa et al, 2022).…”

Section: Powder Bed Fusionmentioning

confidence: 99%

A Short and Technical Review on Lattice Structures Produced by Additive Manufacturing

Özdemir

Korkmaz

2023

Prabha Materials Science Letters

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Additive manufacturing (AM), which has only relatively recently emerged as one of the most significant sectors, is currently the subject of a great number of research investigations. In contrast to machining, additive manufacturing (AM) is a process that involves the division of items into very thin layers, followed by the production of these layers by stacking previous layers atop one another. AM has found new application areas because to the decrease in weight as well as other advantages in a variety of industries including aviation, automotive, and biomedical. In this manner, features that cannot be acquired from solid materials have been disclosed through the utilization of various forms of lattice structures in accordance with the needs of the application. The design factors that impact the compression behavior of body-centered cubic (BCC) and face-centered cubic (FCC) type lattice structures, which are the most popular types of lattice structures used in additive manufacturing, were explored in this review work.

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Trapped powder removal from sheet-based porous structures based on triply periodic minimal surfaces fabricated by electron beam powder bed fusion

Cited by 29 publications

References 44 publications

Point-of-Care Orthopedic Oncology Device Development

Point-of-Care Orthopedic Oncology Device Development

Complete Removal of Residual Particles and Realization of Mechanical Properties to Improve Osseointegration in Additively Manufactured Ti6Al4 V Scaffolds through Flowing Acid Etching

A Short and Technical Review on Lattice Structures Produced by Additive Manufacturing

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