Customized design and biomechanical property analysis of 3D-printed tantalum intervertebral cages.

BACKGROUND: Intervertebral cages used in clinical applications were often general products with standard specifications, which were challenging to match with the cervical vertebra and prone to cause stress shielding and subsidence. OBJECTIVE: To design and fabricate customized tantalum (Ta) intervertebral fusion cages that meets the biomechanical requirements of the cervical segment. METHODS: The lattice intervertebral cages were customized designed and fabricated by the selective laser melting. The joint and muscle forces of the cervical segment under different movements were analyzed using reverse dynamics method. The stress characteristics of cage, plate, screws and vertebral endplate were analyzed by finite element analysis. The fluid flow behaviors and permeability of three lattice structures were simulated by computational fluid dynamics. Compression tests were executed to investigate the biomechanical properties of the cages. RESULTS: Compared with the solid cages, the lattice-filled structures significantly reduced the stress of cages and anterior fixation system. In comparison to the octahedroid and quaddiametral lattice-filled cages, the bitriangle lattice-filled cage had a lower stress shielding rate, higher permeability, and superior subsidence resistance ability. CONCLUSION: The inverse dynamics simulation combined with finite element analysis is an effective method to investigate the biomechanical properties of the cervical vertebra during movements.

Study on 3D printing process of continuous polyglycolic acid fiber-reinforced polylactic acid degradable composites.

A continuous polyglycolic acid (PGA) fiber-reinforced polylactic acid (PLA) degradable composite was proposed for application in biodegradable load-bearing bone implant. The fused deposition modeling (FDM) process was used to fabricate composite specimens. The influences of the printing process parameters, such as layer thickness, printing spacing, printing speed, and filament feeding speed on the mechanical properties of the PGA fiber-reinforced PLA composites, were studied. The thermal properties of the PGA fiber and PLA matrix were investigated by using differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The internal defects of the as-fabricated specimens were characterized by the micro-X- ray 3D imaging system. During the tensile experiment, a full-field strain measurement system was used to detect the strain map and analysis the fracture mode of the specimens. A digital microscope and field emission electron scanning microscopy were used to observe the interface bonding between fiber and matrix and fracture morphologies of the specimens. The experimental results showed that the tensile strength of specimens was related to their fiber content and porosity. The printing layer thickness and printing spacing had significant impacts on the fiber content. The printing speed did not affect the fiber content but had a slight effect on the tensile strength. Reducing the printing spacing and layer thickness could increase the fiber content. The tensile strength (along the fiber direction) of the specimen with 77.8% fiber content and 1.82% porosity was the highest, reaching 209.32 ± 8.37 MPa, which is higher than the tensile strength of the cortical bone and polyether ether ketone (PEEK), indicating that the continuous PGA fiber-reinforced PLA composite has great potential in the manufacture of biodegradable load-bearing bone implants.

Optimization of 3D Printing Parameters of Biodegradable Polylactic Acid/Hydroxyapatite Composite Bone Plates.

The building parameters of three-dimensional (3D) printed polylactic acid/hydroxyapatite (HA) composite bone plates were optimized by an orthogonal experiment, and the effects of the layer thickness, printing speed, filament feeding speed, and HA content on the bending strengths of the specimens were analyzed. The deformation characteristics of the specimens were studied by 3D full-field strain analysis, and the internal defects of the specimens were analyzed. The effects of different combinations of the process parameters on the cross-sectional shape of the single deposited line, printing temperature, and pressure of the molten material were further analyzed. The results showed that the factors affecting the bending properties were the layer thickness, printing speed, filament feeding speed, and HA content, successively. The optimized process parameters were an HA content of 10%, a layer thickness of 0.1 mm, a printing speed of 30 mm/s, and a filament feeding speed of 0.8 mm/s, and the optimized specimen bending strength was 103.1 ± 5.24 MPa. The deposited line with a flat section shape and width greater than the print spacing helped to reduce the porosity of the specimens. The process parameters that resulted in large high-temperature areas and a high extrusion pressure could better promote material fusion.