3D printer-driven design of a non-assembly titanium surgical instrument using compliant lattice flexures

Metal additive manufacturing is a promising technology for the production of functional medical products, due to its high shape complexity and resolution, and ability to withstand sterilization temperatures. This study explores the possibility of designing a completely non-assembly steerable surgical instrument using Selective Laser Melting....

Quality of AM implants in biomedical application

Additive manufacturing (AM) technologies, particularly those based on powder bed fusion (PBF), most notably, selective laser melting (SLM) for metals, have in recent years emerged as unique fabrication methods for patient-specific implants made of metals and their alloys. The ability to manufacture complex geometries together with the other...

Corrosion and Microstructural Investigation on Additively Manufactured 316L Stainless Steel: Experimental and Statistical Approach

The use of metal additive manufacturing (AM) has strongly increased in the industry during the last years. More specifically, selective laser melting (SLM) is one of the most used techniques due to its numerous advantages compared to conventional processing methods. The purpose of this study is to investigate the effects of process parameters...

Effect of Hot Isostatic Pressing on the Microstructure of Directionally Solidified Nickel Alloy After SLM

The paper investigates the effect of hot isostatic pressing of single-crystal nickel-based alloy manufactured by selective laser melting (SLM) with a high-temperature substrate preheating. A study of the structure and phase composition of the material before and after treatment has been carried out. It was found that as a result of such...

Heat treatment effect on the structure formation of directionally solidified nickel alloy after SLM

The aim of this study was to determine the influence of heat treatment on the microstructure of single-crystal nickel-based alloy manufactured by selective laser melting with a high-temperature substrate preheating. The change of gamma/gamma prime -phases ratio was established as a result of various heat treatment modes.

Effects of heat treatment on microstructure and properties of selective laser melted titanium aluminide alloy

Titanium aluminide alloys are considered to be attractive materials for aerospace and automotive high-temperature applications due to their high specific strength, creep resistance, and heat resistance. However, their brittleness makes it difficult to manufacture complex-shaped components of these alloys using conventional processes making...

Additive manufacturing of non-assembly deployable mechanisms for the treatment of large bony defects

Porous biomaterials are often used to treat large bony defects or fractured vertebras. Most of such biomaterials are made of metals and their alloys and have a pre-defined, fixed shape. Due to their predefined fixed shape, however, they are not suitable for implantation through minimally invasive surgical procedures. To overcome this problem,...

Effect of surface morphology on the Ti–Ti adhesive bond performance of Ti6Al4V parts fabricated by selective laser melting

Surface morphology of adherends is an important factor to take into consideration when studying and improving the performance of an adhesive bonded joint. In this study, the adhesion performance three different surface morphologies of Selective Laser Melted (SLM) Ti6Al4V was studied. The three surface morphologies were created by manufacturing...

Cracks formation in nickel-based single crystal alloy manufactured by selective laser melting

The aim of this study was to determine the influence of selective laser melting (SLM) process parameters on the formation of cracks in nickel-based single crystal alloy. Several sets of laser scanning parameters, with varied laser power, scanning speed and hatch distance, thus resulting in different volumetric and linear energy densities,...

Microstructure and mechanical properties of tial-based alloy produced by selective laser melting

Additive Manufacturing (AM) is an attractive way of producing parts of intermetallic titanium alloys. However, high brittleness of these alloys makes it challenging to produce crack-free intermetallic parts by AM. One way to overcome this problem is to use high-temperature powder-bed preheating. In this paper, Ti-48Al-2Cr-2Nb alloy was...

Numerical analysis of the effect of the scan strategy on the residual stress in the multi-laser selective laser melting

The inevitably formed residual stress in the Selective Laser Melting (SLM) process leads to distortion, crack and even delamination of the workpiece. Single laser is commonly applied during SLM processing. However, its productivity is much lower than multiple lasers. In addition, the research of residual stress with multi-laser condition...

Additive manufacturing of Ti-48Al-2Cr-2Nb alloy using gas atomized and mechanically alloyed plasma spheroidized powders

In this paper, laser powder-bed fusion (L-PBF) additive manufacturing (AM) with a high-temperature inductive platform preheating was used to fabricate intermetallic TiAl-alloy samples. The gas atomized (GA) and mechanically alloyed plasma spheroidized (MAPS) powders of the Ti-48Al-2Cr-2Nb (at. %) alloy were used as the feedstock material. The...

Corrosion fatigue behavior of additively manufactured biodegradable porous iron

The corrosion fatigue behavior of additively manufactured topologically ordered porous iron based on diamond unit cells was studied for the first time to understand its response to cyclic loading in a simulated physiological environment. The material exhibited high fatigue resistance with fatigue strengths being 70% and 65% of yield stress in...

Beyond the orthogonal: On the influence of build orientation on fatigue crack growth in SLM Ti-6Al-4V

A challenge in developing an in-depth understanding of the crack growth resistance of Additively Manufactured materials is the fact that their mechanical properties have been shown to be both process and part-geometry dependent. Up to now, no studies have investigated the influence of off-axis (beyond the three orthogonal build orientations)...

Mechanics of Bone-substituting Meta-biomaterials

One of the main functions of bone is to support the human body mechanically. To fulfil its complex role, bone possesses unique mechanical properties: it is stiff enough to resist deformation while being able to absorb energy.<br/>In this thesis, a comprehensive study has been carried out using analytical methods, numerical methods and...

Effect of porosity variation strategy on the performance of functionally graded Ti-6Al-4V scaffolds for bone tissue engineering

Functionally graded scaffold (FGS) is designed to mimic the morphology, mechanical and biological properties of natural bone closely. Porosity variation strategy between different regions in FGS plays a crucial role in influencing its mechanical and biological performance. A combination of modeling tool and scripting language can effectively...

Additively manufactured metallic porous biomaterials based on minimal surfaces: A unique combination of topological, mechanical, and mass transport properties

Porous biomaterials that simultaneously mimic the topological, mechanical, and mass transport properties of bone are in great demand but are rarely found in the literature. In this study, we rationally designed and additively manufactured (AM) porous metallic biomaterials based on four different types of triply periodic minimal surfaces (TPMS)...

Additively manufactured biodegradable porous magnesium

An ideal bone substituting material should be bone-mimicking in terms of mechanical properties, present a precisely controlled and fully interconnected porous structure, and degrade in the human body to allow for full regeneration of large bony defects. However, simultaneously satisfying all these three requirements has so far been highly...