Additive manufactured porous biomaterials targeting orthopedic implants: A suitable combination of mechanical, physical and topological properties.

Orthopedic implants are under incessant advancement to improve their interactions with surrounding bone tissue aiming to ensure successful outcomes for patients. A successful biological interaction between implant and surrounding bone depends on the combination of mechanical, physical and topological properties. Hence, Ti6Al4V cellular structures appear as very promising solutions towards the improvement of conventional orthopedic implants. This work addresses a set of fundamental tools that allow improving the design of Ti6Al4V cellular structures produced by Selective Laser Melting (SLM). Three-point bending tests were carried out to estimate the elastic modulus of the produced structures. Morphological analysis allowed to evaluate the dimensional differences that were noticed between the model CAD and the SLM structures. Finite element models (adjusted CAD) were constructed with the experimentally obtained dimensions to replicate the mechanical response of the SLM structures. Linear correlations were systematically found for the dimensions of the SLM structures as a function of the designed model CAD dimensions. This has also been observed for the measured porosities as a function of the designed CAD models. This data can be used in further FE analyses as design guidelines to help engineers fabricating near-net-shape SLM Ti6Al4V cellular structures. Besides, polished and sandblasted surface treatments performed on the Ti6Al4V cellular structures allowed to obtain suitable properties regarding roughness and wettability when compared to as-produced surfaces. The capillarity tests showed that all the analyzed Ti6Al4V structures are able to transport fluid along its structure. The cell viability tests demonstrate Ti6Al4V cellular structures SLM produced did not release toxic substances to the medium, indicating that these structures can assure a suitable environment for cells to proliferate and attach. This study proposes a design methodology for Ti6Al4V cellular structures, that owe suitable mechanical properties but also provide a proper combination of porosity, roughness, wettability, capillarity and cell viability, all of them relevant for orthopedic applications. A Ti6Al4V cellular structured hip implant prototype gathering the suitable features addressed in this study was successfully SLM-produced.

Ti6Al4V laser surface preparation and functionalization using hydroxyapatite for biomedical applications.

This work presents a novel texture design for implants surface functionalization, through the creation of line-shaped textures on Ti6Al4V surfaces and subsequent sintering of hydroxyapatite (HAp) powder into the designated locations. HAp-rich locations were designed to avoid HAp detachment during insertion, thus guaranteeing an effective osseointegration. This process starts by creating textured lines using a Nd:YAG laser, filling these lines with HAp powder and sintering HAp using a CO2 laser. The adhesion of HAp is known to be influenced by HAp sintering parameters, especially laser power and scanning speed and also by the textured lines manufacturing. Different laser parameters combinations were used to assess the sintering and adhesion of HAp to the textured lines. HAp adhesion was assessed by performing high energy ultrasonic cavitation tests and sliding tests mimicking an implant insertion, with Ti6Al4V/HAp specimens sliding against animal bone. The HAp content retained after these tests was measured and results showed that an excellent HAp sintering and adhesion was achieved when using a scan speed of 1 mm/s and laser power between 9 and 9.6 W. It is important to emphasize that results indicated that the HAp bioactivity was maintained when using these conditions, validating this functionalization process for the production of hip prosthesis with improved bioactivity. © 2017 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 106B: 1534-1545, 2018.

Bioactive materials driven primary stability on titanium biocomposites.

The Ti6Al4V alloy constitutes an alternative choice to the most common metal-polymer solutions for total hip arthroplasty (THA) due to good biocompatibility, optimal mechanical properties and high load bearing capacity. However, as Ti6Al4V is not bioactive in its conventional form, hydroxyapatite (HAp) and tricalcium phosphate (TCP) have been widely used as coatings of metal prostheses due to their osteogenic properties and ability to form strong bonds with bone tissue. A promising approach consists in creating a bioactive surface metal matrix composite Ti6Al4V+ß-TCP or Ti6Al4V+HAp, obtained by hot pressing (HP) of powders. In this work, the tribological performance of Ti6Al4V+ß-TCP and Ti6Al4V+HAp composites is studied to evaluate the frictional response and surface damage representative of prosthesis implantation, key factors in bone fixation. Biocomposites with 10vol% ß-TCP and 10vol% Hap, as well as base titanium alloy, were prepared by HP with two surface finishing conditions - polished (Ra=0.3-0.5µm) and sandblasted (Ra=2.1-2.5µm) - for tribological testing against bovine cortical bone tissue. The static friction increases with surface roughness (from 0.20 to 0.60), whereas the kinetic regime follows an inverse trend for the biocomposites. In contrast with current knowledge, this study shows that an implant design solution based on Ti6Al4V+ß-TCP or Ti6Al4V+HAp biocomposites with polished surfaces results in an improved primary stability of implants, when compared to traditional rough surfaces. Moreover, it is also expected that the secondary stability will improve due to the adhesion between bone and HAp/ß-TCP, increasing the overall stability of the implant.

Fracture characterization of human cortical bone under mode II loading using the end-notched flexure test.

Fracture characterization of human cortical bone under mode II loading was analyzed using a miniaturized version of the end-notched flexure test. A data reduction scheme based on crack equivalent concept was employed to overcome uncertainties on crack length monitoring during the test. The crack tip shear displacement was experimentally measured using digital image correlation technique to determine the cohesive law that mimics bone fracture behavior under mode II loading. The developed procedure was validated by finite element analysis using cohesive zone modeling considering a trapezoidal with bilinear softening relationship. Experimental load-displacement curves, resistance curves and crack tip shear displacement versus applied displacement were used to validate the numerical procedure. The excellent agreement observed between the numerical and experimental results reveals the appropriateness of the proposed test and procedure to characterize human cortical bone fracture under mode II loading. The proposed methodology can be viewed as a novel valuable tool to be used in parametric and methodical clinical studies regarding features (e.g., age, diseases, drugs) influencing bone shear fracture under mode II loading.

Mixed-mode I+II fracture characterization of human cortical bone using the Single Leg Bending test.

Mixed-mode I+II fracture characterization of human cortical bone was analyzed in this work. A miniaturized version of the Single Leg Bending test (SLB) was used owing to its simplicity. A power law criterion was verified to accurately describe the material fracture envelop under mixed-mode I+II loading. The crack tip opening displacements measured by digital image correlation were used in a direct method to determine the cohesive law mimicking fracture behavior of cortical bone. Cohesive zone modeling was used for the sake of validation. Several fracture quantities were compared with the experimental results and the good agreement observed proves the appropriateness of the proposed procedure for fracture characterization of human bone under mixed-mode I+II loading.

Bone fracture characterization under mixed-mode I+II loading using the single leg bending test.

Fracture under mixed-mode I+II was induced in bovine cortical bone tissue using a developed miniaturized version of the single leg bending test (SLB). Due to the difficulty in crack length monitoring in the course of the test, an equivalent crack method based on specimen compliance and beam theory was adopted as a data reduction scheme. The method was applied to the experimental results in order to obtain the Resistance curves in each loading mode. The determined fracture energy is well described by an energetic power law whose exponent is below one, which means that the linear energetic criterion is not applicable to this material. The proposed procedure was numerically validated by means of a cohesive mixed-mode I+II damage model with bilinear softening. It was concluded that the miniaturized version of the SLB test is adequate for mixed-mode I+II fracture characterization of bone for a constant mode ratio.

Bone fracture characterization using the end notched flexure test.

A miniaturized version of the end notch flexure test was used in the context of pure mode II fracture characterization of bovine cortical bone. To overcome the difficulties intrinsic to crack length monitoring during its propagation an equivalent crack method was employed as data reduction scheme. The proposed method was validated numerically by means of a finite element analysis including a cohesive zone modeling and subsequently applied to experimental results to determine the fracture energy of bone under pure mode II loading. Finally, a cohesive law representative of fracture behavior of each specimen was determined employing an inverse method, considering a trapezoidal shape for the softening law. The consistency of the obtained results leads to the conclusion that the trapezoidal law is adequate to simulate fracture behavior of bone under mode II loading. The proposed testing setup and the employed data reduction scheme constitute powerful tools in which concerns fracture characterization of bone under pure mode II loading and can be viewed as the main outcomes of this work.

Fracture characterization of bone under mode II loading using the end loaded split test.

Fracture energy release rate under mode II loading of bovine cortical bone is determined using a miniaturized testing device of the end loaded split test. The energy release rate is evaluated by means of a data reduction scheme based on specimen compliance, beam theory and crack equivalent concept. Experimental tests were carried out to evaluate the Resistance curve which provides a successful method to characterize fracture behavior of quasi-brittle materials like bone. A numerical analysis including a cohesive damage model was used to validate the procedure. It was demonstrated that the end loaded split test and proposed data reduction scheme provide a valuable solution for mode II fracture characterization of bone.

The double cantilever beam test applied to mode I fracture characterization of cortical bone tissue.

The primary objective of this work was to analyse the adequacy of the Double Cantilever Beam (DCB) test in determining fracture toughness under pure mode I loading of cortical bone tissue. A new data reduction scheme based on specimen compliance and the crack equivalent concept was used to overcome the difficulties inherent in crack monitoring during its growth. It provides a complete resistance curve, which is fundamental in estimating the fracture energy. A cohesive zone model was used to simulate damage initiation and propagation, thus assessing the efficacy of the proposed testing method and data reduction scheme. Subsequently, the DCB test was applied to evaluate the mode I fracture energy of hydrated and thermally dehydrated cortical bone tissue from young bovine femur, in the tangential-longitudinal propagation system. The results obtained demonstrate the efficacy of the DCB test and the proposed data reduction scheme on the bone fracture characterization under mode I loading.