Next Generation Orthopaedic Implants by Additive Manufacturing Using Electron Beam Melting

This paper presents some examples of knee and hip implant components containing porous structures and fabricated in monolithic forms utilizing electron beam melting (EBM). In addition, utilizing stiffness or relative stiffness versus relative density design plots for open-cellular structures (mesh and foam components) of Ti-6Al-4V and Co-29Cr-6Mo alloy fabricated by EBM, it is demonstrated that stiffness-compatible implants can be fabricated for optimal stress shielding for bone regimes as well as bone cell ingrowth. Implications for the fabrication of patient-specific, monolithic, multifunctional orthopaedic implants using EBM are described along with microstructures and mechanical properties characteristic of both Ti-6Al-4V and Co-29Cr-6Mo alloy prototypes, including both solid and open-cellular prototypes manufactured by additive manufacturing (AM) using EBM.

[1]  B. Bollen,et al.  Impulse excitation apparatus to measure resonant frequencies, elastic moduli, and internal friction at room and high temperature , 1997 .

[2]  Ola L. A. Harrysson,et al.  Direct Fabrication of Custom Orthopedic Implants Using Electron Beam Melting Technology , 2006 .

[3]  R Deutman,et al.  Total Hip Arthroplasty , 2018 .

[4]  R. Singer,et al.  Cellular Ti-6Al-4V structures with interconnected macro porosity for bone implants fabricated by selective electron beam melting. , 2008, Acta biomaterialia.

[5]  Abhay Pandit,et al.  Fabrication methods of porous metals for use in orthopaedic applications. , 2006, Biomaterials.

[6]  David C. Dunand,et al.  Processing of Titanium Foams , 2004 .

[7]  K. Leong,et al.  The design of scaffolds for use in tissue engineering. Part I. Traditional factors. , 2001, Tissue engineering.

[8]  George A. Ksander,et al.  Biological and Biomechanical Performance of Biomaterials , 1988 .

[9]  O. Harrysson,et al.  Direct metal fabrication of titanium implants with tailored materials and mechanical properties using electron beam melting technology , 2008 .

[10]  J. Cahoon.  On the corrosion products of orthopedic implants. , 1973, Journal of biomedical materials research.

[11]  J.L. Martinez,et al.  Comparison of Microstructures and Mechanical Properties for Solid and Mesh Cobalt-Base Alloy Prototypes Fabricated by Electron Beam Melting , 2010 .

[12]  L. Murr,et al.  Microstructure and mechanical properties of open-cellular biomaterials prototypes for total knee replacement implants fabricated by electron beam melting. , 2011, Journal of the mechanical behavior of biomedical materials.

[13]  J. Kruth,et al.  A study of the microstructural evolution during selective laser melting of Ti–6Al–4V , 2010 .

[14]  M. Wolcott.  Cellular solids: Structure and properties , 1990 .

[15]  L. Murr,et al.  Next-generation biomedical implants using additive manufacturing of complex, cellular and functional mesh arrays , 2010, Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences.

[16]  V. Altuzar,et al.  Atmospheric pollution profiles in Mexico City in two different seasons , 2003 .

[17]  Ryan B. Wicker,et al.  Open-cellular copper structures fabricated by additive manufacturing using electron beam melting , 2011 .

[18]  L. Murr,et al.  Microstructure and mechanical behavior of Ti-6Al-4V produced by rapid-layer manufacturing, for biomedical applications. , 2009, Journal of the mechanical behavior of biomedical materials.

[19]  Joseph D. Bronzino,et al.  The Biomedical Engineering Handbook , 1995 .

[20]  Richard Dashwood,et al.  Titanium foams for biomedical applications: a review , 2010 .

[21]  Wenguang Zhang,et al.  Fabrication and characterization of porous Ti6Al4V parts for biomedical applications using electron beam melting process , 2009 .

[22]  L. Murr,et al.  Open-Cellular Co-Base and Ni-Base Superalloys Fabricated by Electron Beam Melting , 2011, Materials.

[23]  Tabatabaei Qomi,et al.  The Design of Scaffolds for Use in Tissue Engineering , 2014 .

[24]  W. Marsden.  I and J , 2012 .