Method of computational design for additive manufacturing of hip endoprosthesis based on basic-cell concept.

Endoprosthetic hip replacement is the conventional way to treat osteoarthritis or a fracture of a dysfunctional joint. Different manufacturing methods are employed to create reliable patient-specific devices with long-term performance and biocompatibility. Recently, additive manufacturing has become a promising technique for the fabrication of medical devices, because it allows to produce complex samples with various structures of pores. Moreover, the limitations of traditional fabrication methods can be avoided. It is known that a well-designed porous structure provides a better proliferation of cells, leading to improved bone remodeling. Additionally, porosity can be used to adjust the mechanical properties of designed structures. This makes the design and choice of the structure's basic cell a crucial task. This study focuses on a novel computational method, based on the basic-cell concept to design a hip endoprosthesis with an unregularly complex structure. A cube with spheroid pores was utilized as a basic cell, with each cell having its own porosity and mechanical properties. A novelty of the suggested method is in its combination of the topology optimization method and the structural design algorithm. Bending and compression cases were analyzed for a cylinder structure and two hip implants. The ability of basic-cell geometry to influence the structure's stress-strain state was shown. The relative change in the volume of the original structure and the designed cylinder structure was 6.8%. Computational assessments of a stress-strain state using the proposed method and direct modeling were carried out. The volumes of the two types of implants decreased by 9% and 11%, respectively. The maximum von Mises stress was 600 MPa in the initial design. After the algorithm application, it increased to 630 MPa for the first type of implant, while it is not changing in the second type of implant. At the same time, the load-bearing capacity of the hip endoprostheses was retained. The internal structure of the optimized implants was significantly different from the traditional designs, but better structural integrity is likely to be achieved with less material. Additionally, this method leads to time reduction both for the initial design and its variations. Moreover, it enables to produce medical implants with specific functional structures with an additive manufacturing method avoiding the constraints of traditional technologies.

Nanocomposite orthopaedic bone cement combining long-acting dual antimicrobial drugs.

Antibiotic loaded bone cements are widely used in total joint replacement (TJR); despite many limitations such as a burst release which leads to antibiotic concentration below inhibitory levels and possibly contributing to the selection of antibiotic resistant strains. In order to address such limitations and to simultaneously address antibiotic resistance and short-term antimicrobial activity, we developed a nanocomposite bone cement capable of providing a controlled release of antimicrobial agents from bone cement to act as prophylaxis or treatment against prosthetic joint infections (PJIs). Gentamicin and chlorhexidine were loaded in combination on silica nanoparticles surface using layer-by-layer coating technique (LbL) combining hydrolysable and non-hydrolysable polymers. The drug release from the nanocomposite continued for >50 days at concentrations higher than the commercial formulation containing the same amount of antimicrobial drugs, where burst release for few days were observed. Moreover, the nanocomposite bone cement showed superior antimicrobial inhibition without adversely affecting the mechanical properties or the ability of osteoblasts to grow. In vivo experiments with an infected bone lesion model along with mass-spectrometric analysis also provided further evidence of efficacy and safety of the implanted nanocomposite material as well as its prolonged drug eluting profile. The developed nanocomposite bone cement has the potential to reduce PJIs and enable treatment of resistant established infections; moreover, the newly developed LbL based nano-delivery system may also have wider applications in reducing the threat posed by antimicrobial resistance.

Three-Dimensional-Printed Polymeric Cores for Methane Hydrate Enhanced Growth.

Polymeric models of the core prepared with a Raise3D Pro2 3D printer were employed for methane hydrate formation. Polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), carbon fiber reinforced polyamide-6 (UltraX), thermoplastic polyurethane (PolyFlex), and polycarbonate (ePC) were used for printing. Each plastic core was rescanned using X-ray tomography to identify the effective porosity volumes. It was revealed that the polymer type matters in enhancing methane hydrate formation. All polymer cores except PolyFlex promoted the hydrate growth (up to complete water-to-hydrate conversion with PLA core). At the same time, changing the filling degree of the porous volume with water from partial to complete decreased the efficiency of hydrate growth by two times. Nevertheless, the polymer type variation allowed three main features: (1) managing the hydrate growth direction via water or gas preferential transfer through the effective porosity; (2) the blowing of hydrate crystals into the volume of water; and (3) the growth of hydrate arrays from the steel walls of the cell towards the polymer core due to defects in the hydrate crust, providing an additional contact between water and gas. These features are probably controlled by the hydrophobicity of the pore surface. The proper filament selection allows the hydrate formation mode to be set for specific process requirements.

Determination of Sessile Drop Wetting Angle Based on µCT without the Direct Angle Measurement.

Wettability is an important factor that controls the position and transport of fluids in the porous structure of a hydrocarbon reservoir. Direct quantitative wettability measurement methods include determination of the contact angle. One of the popular laboratory methods for its measurement is the sessile drop method, where the droplet of liquid is set onto the solid sample surface and the angle between liquid and solid phases in a 2D profile image is measured using a high-resolution optical subsystem. However, this method has disadvantages connected with three complex factors: two-dimensionality of data, image resolution, and the presence of wetting domains on the solid surface. In this work, we propose a method based on 3D µCT scanning of a sessile drop on the surface of a material and determination of the value of the wetting angle using drop height and volume measurements. Since the contact angle is not measured directly, this makes it possible to obtain averaged contact angle values for the entire droplet and leads to more stable values for individual measurements in comparison with the standard optical method. The results demonstrate that contact angles obtained using the µCT method differ from the values obtained by various fitting techniques of the 2D optical method: µCT-values are higher for hydrophilic interaction by 4-6° and lower for hydrophobic interaction by 12-17°. Such differences are associated with the lower susceptibility of the proposed method to the influence of the gravitational effect, which leads to a flattening of the droplet shape and distortion of angle measurements on the 2D projections. However, the described method showed close contact angles for water drops on a polytetrafluoroethylene surface with values obtained in microgravity and can be helpful for its prediction. It also has relatively low sensitivity to the absolute values of the drop volume and drop segmentation errors.