Biological Characterization of Ti6Al4V Additively Manufactured Surfaces: Comparison Between Ultrashort Laser Texturing and Conventional Post-Processing.

Among Additive Manufacturing (AM) technologies, Laser Powder Bed Fusion (LPBF) has made a great contribution to optimizing the production of customized implant materials. However, the design of the ideal surface topography, capable of exerting the best biological effect without drawbacks, is still a subject of study. The aim of the present study is to topographically and biologically characterize AM-produced Ti6Al4V ELI (Extra Low Interstitial) samples by comparing different surface finishing. Vertically and horizontally samples are realized by LPBF with four surface finishing conditions (as-built, corundum-sandblasted, zirconia-sandblasted, femtosecond laser textured). Bioactivity in vitro tests are performed with human osteoblasts evaluating morphology, metabolic activity, and differentiation capabilities in direct contact with surfaces. Scanning electron microscope and profilometry analysis are used to evaluate surface morphology and samples' roughness with and without cells. All tested surfaces show good biocompatibility. The influence of material surface features is evident in the early evaluation, with the most promising results of morphological study for laser texturing. Deposition orientations seem to influence metabolic activities, with XZ orientation more effective than XY. Current data provide the first positive feedback on the biocompatibility of laser texturing finishing, still poorly described in the literature, and support the future clinical development of devices produced with a combination of LPBF and different finishing treatments.

Impact of Surface Finishing on Ti6Al4V Voronoi Additively Manufactured Structures: Morphology, Dimensional Deviation, and Mechanical Behavior.

Additively manufactured medical devices require proper surface finishing before their use to remove partially adhered particles and provide adequate surface roughness. The literature widely investigates regular lattice structures-mainly scaffolds with small pores to enhance osseointegration; however, only a few studies have addressed the impact of surface finishing on the dimensional deviation and the global and local mechanical responses of lattice samples. Therefore, the current research investigates the impact of biomedical surface finishing (i.e., corundum sandblasting and zirconia sandblasting) on Voronoi lattice structures produced by laser powder bed fusion (LPBF) with large pores and different thicknesses on the surface morphology and global and local mechanical behaviors. MicroCT and SEM are performed for the assessment of dimensional mismatch and surface evaluation. The mechanical properties are investigated with 2D digital image correlation (DIC) in quasi-static compression tests to estimate the impact of surface finishes on local maps of strain. In the quasi-static tests, both the global mechanical performances, as expected, and local 2D DIC strain maps were mainly affected by the strut thickness, and the impact of different surface finishings was irrelevant; on the contrary, different surface finishing processes led to differences in the dimensional deviation depending on the strut thickness. These results are relevant for designing lattice structures with thin struts that are integrated into medical prostheses that undergo AM.

Effect of trabecular architectures on the mechanical response in osteoporotic and healthy human bone.

Research at the mesoscale bone trabeculae arrangement yields intriguing results that, due to their clinical resolution, can be applied in clinical field, contributing significantly to the diagnosis of bone-related diseases. While the literature offers quantitative morphometric parameters for a thorough characterization of the mesoscale bone network, there is a gap in understanding relationships among them, particularly in the context of various bone pathologies. This research aims to bridge these gaps by offering a quantitative evaluation of the interplay among morphometric parameters and mechanical response at mesoscale in osteoporotic and non-osteoporotic bones. Bone mechanical response, dependent on trabecular arrangement, is defined by apparent stiffness, computationally calculated using the Gibson-Ashby model. Key findings indicate that: (i) in addition to bone density, measured using X-ray absorptiometry, trabecular connectivity density, trabecular spacing and degree of anisotropy are crucial parameters for characterize osteoporosis state; (ii) apparent stiffness values exhibit strong correlations with bone density and connectivity density; (iii) connectivity density and degree of anisotropy result the best predictors of mechanical response. Despite the inherent heterogeneity in bone structure, suggesting the potential benefit of a larger sample size in the future, this approach presents a valuable method to enhance discrimination between osteoporotic and non-osteoporotic samples.

In Vitro Assessment of the Neuro-Compatibility of Fe-20Mn as a Potential Bioresorbable Material for Craniofacial Surgery.

Background and Objectives: Spring-assisted surgery is a popular option for the treatment of non-syndromic craniosynostosis. The main drawback of this procedure is the need for a second surgery for spring removal, which could be avoided if a distractor material could be metabolised over time. Iron-Manganese alloys (FeMn) have a good trade-off between degradation rate and strength; however, their biocompatibility is still debated. Materials and Methods: In this study, the neuro-compatibility of Fe-20Mn (wt.%) was assessed using standard assays. PC-12 cells were exposed to Fe-20Mn (wt.%) and stainless steel via indirect contact. To examine the cytotoxicity, a Cell Tox Green assay was carried out after 1, 2, and 3 days of incubation. Following differentiation, a neurite morphological examination after 1 and 7 days of incubation time was carried out. The degradation response in modified Hank's solution at 1, 3, and 7 days was investigated, too. Results: The cytotoxicity assay showed a higher toxicity of Fe-20Mn than stainless steel at earlier time points; however, at the latest time point, no differences were found. Neurite morphology was similar for cells exposed to Fe-20Mn and stainless steel. Conclusions: In conclusion, the Fe-20Mn alloy shows promising neuro-compatibility. Future studies will focus on in vivo studies to confirm the cellular response to Fe-20Mn.

Bactericidal Activity of Silver-Doped Chitosan Coatings via Electrophoretic Deposition on Ti6Al4V Additively Manufactured Substrates.

Prosthetic reconstruction can serve as a feasible alternative, delivering both functional and aesthetic benefits to individuals with hand and finger injuries, frequent causes of emergency room visits. Implant-related infections pose significant challenges in arthroplasty and osteosynthesis procedures, contributing to surgical failures. As a potential solution to this challenge, this study developed a new class of silver (Ag)-doped chitosan (CS) coatings via electrophoretic deposition (EPD) on osseointegrated prostheses for infection therapy. These coatings were successfully applied to additively manufactured Ti6Al4V ELI samples. In the initial phase, the feasibility of the composite coating was assessed using the Thermogravimetric Analysis (TGA) and Attenuated Total Reflection (ATR) techniques. The optimized structures exhibited impressive water uptake in the range of 300-360%. Codeposition with an antibacterial agent proved effective, and scanning electron microscopy (SEM) was used to examine the coating morphology. Biologically, CS coatings demonstrated cytocompatibility when in direct contact with a fibroblast cell line (L929) after 72 h. When exposed to the Staphylococcus epidermidis strain (ATCC 12228), these coatings inhibited bacterial growth and biofilm formation within 24 h. These findings underscore the significant potential of this approach for various applications, including endoprostheses like hip implants, internal medical devices, and transcutaneous prostheses such as osseointegrated limb prosthetics for upper and lower extremities.

A biomechanical study of osseointegrated patient-matched additively manufactured implant for treatment of thumb amputees.

Thumb amputations leads to 50 % loss in hand functionality. To date, silicone vacuum prosthesis and autologous transplantation are the most adopted treatment solutions: nevertheless, vacuum prostheses lack in stability and cause skin issue and surgical treatment is not always accepted by patients. Osseointegrated implants were demonstrated to enhance stability, restore osseoperception and increase the time of prosthesis use. Thumb amputations present varying stump sizes: a standard size implant cannot address specificity of each patient, while a patient matched solution can meet surgeon requirements, by geometrical features of implant. The fixture presented in the current paper is the first additively manufactured patient matched osseointegrated implant for the treatment of thumb amputees. The current work aims to verify and validate a predictive finite element model (FEM) for mechanical strength of the presented fixture. FEM was demonstrated to correctly evaluate the mechanical strength of patient matched device. Minimum strength requirements were calculated in different core diameters: FEM were experimentally validated. Safety factor of 1.5 was guaranteed. Finally, considerations on performance of the prototype were carried out by means of insertion tests in Sawbones and axial pull-out force assessment. Cadaver tests to evaluate the entire procedure and production process are ongoing.

Osseointegrated Metallic Implants for Finger Amputees: A Review of the Literature.

Digital trauma amputations and digital agenesis strongly affect the functionality and aesthetic appearance of the hand. Autologous reconstruction is the gold standard of treatment. Unfortunately, microsurgical options and transplantation procedures are not possible for patients who present contraindications or refuse to undergo transplantation from the toe (e.g. toe-to-thumb transplantation). To address these issues, osseointegrated finger prostheses are a promising alternative. The functional assessments registered during follow-up confirmed the promising outcomes of osseointegrated prostheses in the treatment of hand finger amputees. This review outlines (a) a detailed analysis of osseointegrated finger metallic components of the implants, (b) the surgical procedures suggested in the literature, and (c) the functional assessments and promising outcomes that demonstrate the potential of these medical osseointegrated devices in the treatment of finger amputees.

Understanding the Role of Surface Modification of Randomized Trabecular Titanium Structures in Bone Tissue Regeneration: An Experimental Study.

Background and Objectives: Three-dimensional (3D) metallic trabecular structures made by additive manufacturing (AM) technologies promote new bone formation and osteointegration. Surface modifications by chemical treatments can improve the osteoconductive properties of metallic structures. An in vivo study in sheep was conducted to assess the bone response to randomized trabecular titanium structures that underwent a surface modification by chemical treatment compared to the bone response to the untreated specimens. Material and Methods: Sixteen specimens with a randomized trabecular titanium structure were implanted in the spongious bone of the distal femur and proximal tibia and the cortical bone of the tibial diaphysis of two sheep. Of them, eight implants had undergone a chemical treatment (treated) and were compared to eight implants with the same structure but native surfaces (native). The sheep were sacrificed at 6 weeks. Surface features of the lattice structures (native and treated) were analyzed using a 3D non-contact profilometer. Compression tests of 18 lattice cubes were performed to investigate the mechanical properties of the two structures. Excellent biocompatibility for the trabecular structures was demonstrated in vitro using a cell mouse fibroblast culture. Histomorphometric analysis was performed to evaluate bone implant contact and bone ingrowth. Results: A compression test of lattice cubic specimens revealed a comparable maximum compressive strength value between the two tested groups (5099 N for native surfaces; 5558 N for treated surfaces; p > 0.05). Compared to native surfaces, a homogenous formation of micropores was observed on the surface of most trabeculae that increased the surface roughness of the treated specimens (4.3 versus 3.2 µm). The cellular viability of cells seeded on three-dimensional structure surfaces increased over time compared to that on plastic surfaces. The histomorphometric data revealed a similar behavior and response in spongious and cortical bone formation. The percentage of the implant surface in direct contact with the regenerated bone matrix (BIC) was not significantly different between the two groups either in the spongious bone (BIC: 27% for treated specimens versus 30% for native samples) or in the cortical bone (BIC: 75% for treated specimens versus 77% for native samples). Conclusions: The results of this study reveal rapid osseointegration and excellent biocompatibility for the trabecular structure regardless of surface treatment using AM technologies. The application of implant surfaces can be optimized to achieve a strong press-fit and stability, overcoming the demand for additional chemical surface treatments.

Heat Treatments for Stress Relieving AlSi9Cu3 Alloy Produced by Laser Powder Bed Fusion.

The present work explores the effect of a stress relieving heat treatment on the microstructure, tensile properties and residual stresses of the laser powder bed fused AlSi9Cu3 alloy. In fact, the rapid cooling rates together with subsequent heating/cooling cycles occurred during layer by layer additive manufacturing production make low temperature heat treatments desirable for promoting stress relaxation as well as limited grain growth: this combination can offer the opportunity of obtaining the best compromise between high strength, good elongation to failure and limited residual stresses. The microstructural features were analysed, revealing that the high cooling rate, induced by the process, caused a large supersaturation of the aluminum matrix and the refinement of the eutectic structure. Microhardness versus time curve, performed at 250 °C, allowed to identify a stabilization of the mechanical property at a duration of 25 h. The microstructure and the mechanical properties of the samples heat treated at 25 h and at 64 h, considered as a reference for the conventionally produced alloy, were compared with the ones of the as-built alloy. Finally, it was shown that a 59% reduction of the principal residual stresses could be achieved after the 25 h-long treatment and such evolution was correlated to the mechanical behaviour.

CoCrMo alloys ions release behavior by TiNbN coating: an in vitro study.

The aim of the study was to show in vitro the greater inertness to the corrosion body fluid of TiNbN coating than the CoCrMo alloy substrate. The prosthetic component under study was a femoral component of total knee prosthesis in CoCrMo alloy coated in TiNbN with Physical Vapor Deposition technique immersed in static Hank's balanced salt solution (HBS) (pH = 6) for at least 34 months at a constant temperature of 37 °C. Another uncoated prosthetic component of CoCrMo alloy with the same type and size was left in static immersion in the same solution and for the same period of time. Scanning electron microscope (SEM) analysis was performed to investigate adhesion and proliferation at 24, 48, 72 h after seeding of 104 sub-confluents osteoblast-like cells (SaOS-2) cells on scaffold. The results of the study showed a reduction in the concentration of the metal ions released from the TiNbN-coated femoral component surface compared to the uncoated surface in the HBS solution. The overall reduction of the ions for the TiNbN-coated femoral component compared to the uncoated one was 80.1 ± 2%, 62.5% ± 8% and 48% ± 10% for Co, Cr, Mo, respectively (p < 0.01). SEM analysis confirmed the healthy state of the cells, the cellular adhesion and proliferation of SaOS-2 on the TiNbN-coated specimen. Although the results observed in vitro for the TiNbN coating are encouraging, clinical studies are certainly needed to be performed in order to understand how these positive findings can be translated in vivo and to determine the clinical benefit of TiNbN coating.

Phase Transformations in the CeO2-Sm2O3 System: A Multiscale Powder Diffraction Investigation.

The structure evolution in the CeO2-Sm2O3 system is revisited by combining high resolution synchrotron powder diffraction with pair distribution function (PDF) to inquire about local, mesoscopic, and average structure. The CeO2 fluorite structure undergoes two phase transformations by Sm doping, first to a cubic (C-type) and then to a monoclinic (B-type) phase. Whereas the C to B-phase separation occurs completely and on a long-range scale, no miscibility gap is detected between fluorite and C-type phases. The transformation rather occurs by growth of C-type nanodomains embedded in the fluorite matrix, without any long-range phase separation. A side effect of this mechanism is the ordering of the oxygen vacancies, which is detrimental for the application of doped ceria as an electrolyte in fuel cells. The results are discussed in the framework of other Y and Gd dopants, and the relationship between nanostructuring and the above equilibria is also investigated.