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Bio-Design and Manufacturing  2023 Vol.6 No.2 P.121-135

http://doi.org/10.1007/s42242-022-00222-2


Direct ink writing to fabricate porous acetabular cups from titanium alloy


Author(s):  Naima Valentin, Weijian Hua, Ashish K. Kasar, Lily Raymond, Pradeep L. Menezes & Yifei Jin

Affiliation(s):  Mechanical Engineering Department, University of Nevada, Reno, Reno, NV 89557, USA

Corresponding email(s):   yifeij@unr.edu

Key Words:  Acetabular cup, Direct ink writing, Titanium alloy, Bentonite, Heat treatment


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Naima Valentin, Weijian Hua, Ashish K. Kasar, Lily Raymond, Pradeep L. Menezes & Yifei Jin. Direct ink writing to fabricate porous acetabular cups from titanium alloy[J]. Journal of Zhejiang University Science D, 2023, 6(2): 121-135.

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Abstract: 
acetabular cups, which are among the most important implants in total hip arthroplasty, are usually made from titanium alloys with high porosity and adequate mechanical properties. The current three-dimensional (3D) printing approaches to fabricate customized acetabular cups have some inherent disadvantages such as high cost and energy consumption, residual thermal stress, and relatively low efficiency. Thus, in this work, a direct ink writing method was developed to print a cup structure at room temperature, followed by multi-step heat treatment to form microscale porous structure within the acetabular cup. Our method is facilitated by the development of a self-supporting titanium-6 aluminum-4 vanadium (Ti64) ink that is composed of Ti64 particles, bentonite yield-stress additive, ultraviolet curable polymer, and photo-initiator. The effects of Ti64 and bentonite concentrations on the rheological properties and printability of inks were systematically investigated. Moreover, the printing conditions, geometrical limitations, and maximum curing depth were explored. Finally, some complex 3D structures, including lattices with different gap distances, honeycomb with a well-defined shape, and an acetabular cup with uniformly distributed micropores, were successfully printed/fabricated to validate the effectiveness of the proposed method.

内华达大学雷诺分校金翼飞团队│利用直写式3D打印技术制造多孔状钛合金髋臼杯植入物

本研究论文聚焦基于直写技术的多孔状钛合金髋臼杯3D打印方法。髋臼杯是全髋关节置换术中最重要的植入物之一,通常由具有高孔隙率和足够机械性能的钛合金制成。当前用于制造定制化髋臼杯的3D打印方法具有一些固有的缺点,例如高成本和能耗、残余热应力和相对较低的效率等。因此,本文开发了一种基于直写技术的多孔状钛合金髋臼杯3D打印方法,以实现室温下杯体结构的制造,并通过后续多步热处理过程形成微孔结构。该方法的核心是一种自支撑并可光固化的钛合金墨水,由钛合金(Ti64)颗粒,膨润土屈服应力添加剂 (bentonite),紫外光固化聚合物(PEGDA)及光引发剂(photo-initiator)组成。其中,膨润土屈服应力添加剂不但可以在打印过程中提供自支撑性能,还可以在后续热解过程中产生微孔隙结构。本文系统地研究了钛合金和膨润土浓度对流变特性及墨水打印性能的影响,讨论了该方法的打印极限,并最终成功打印了微孔均布的髋臼杯植入物。论文研究的自支撑/光固化墨水可以兼容多种金属或陶瓷材料,为此类材料的制造提供了新的加工方法。

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