Optimisation of the additive manufacturing parameters of polylactic acid (PLA) cellular structures for biomedical applications.

Fused deposition modelling (FDM) is an additive manufacturing technology used to create functional and complex geometries directly from computer-generated models. This technique can be utilised to generate cellular structures with controllable pore size, pore shape, and porosity. Cellular structures are fundamental in orthopaedics scaffolds because of its low elastic modulus, high compressive strength, and adequate cell accommodation spaces. This paper aims at investigating and optimising the FDM additive manufacturing process parameters of polylactic Acid (PLA) for two lattice structures namely Schoen Gyroid and Schwarz Primitive. The effect of additive manufacturing critical process parameters including layer height, flow rate, and print speed on the geometrical accuracy and compressive strength of the specimens were analysed. In addition, other parameters that have minimal effect on the geometrical accuracy of the printed parts were discussed. A Full Factorial Analysis (FFA) using Minitab software was undertaken to identify the perfect combination of printing parameters to provide the most geometrically accurate structure. In this study, samples of the Schoen Gyroid and the Schwarz Primitive lattices and a solid control cylinder were 3D printed using the ideal printing combination to assess the manufacturability, the geometrical accuracy, and the mechanical behaviour of both designs. It was found that the optimised FDM process parameters for the studied cellular structures were a layer height of 0.16 mm, a printing speed of 50 mm/s and a flow rate of 90%. As a result of using these parameters, the solid, Schoen Gyroid and Schwarz Primitive specimens demonstrated elastic moduli values of 951 MPa, 264 MPa, and 221 MPa, respectively. In addition, the Schoen Gyroid and the Schwarz Primitive have reached their stress limits at around 8.68 MPa and 7.06 MPa, respectively. It was noticed that the Schoen Gyroid structure exhibited ∼ 18% higher compressive strength and ∼ 16% higher elastic modulus compared to the Schwarz Primitive structure for the same volume fraction of porosity, overall dimensions, and the manufacturing process parameters. Although both structures revealed mechanical properties that fall within the range of the human trabecular bone, but Schoen Gyroid exhibited improved structural integrity performance that is evident by its post-yield behaviour.

Reconfigurable Multipoint Forming Using Waffle-Type Elastic Cushion and Variable Loading Profile.

There is an increasing demand for flexible, relatively inexpensive manufacturing techniques that can accommodate frequent changes to part design and production technologies, especially when limited batch sizes are required. Reconfigurable multi-point forming (MPF) is an advanced manufacturing technique which uses a reconfigurable die consisting of a set of moveable pins to shape sheet metal parts easily. This study investigates the use of a novel variable thickness waffle-type elastic cushion and a variable punch-loading profile to either eliminate or minimise defects associated with MPF, namely wrinkling, thickness variation, shape deviation, and dimpling. Finite element modelling (FEM), analysis of variance (ANOVA), and the response surface methodology (RSM) were used to investigate the effect of process parameters pertaining to the cushion dimensions and type of loading profile on the aforementioned defects. The results of this study indicate that the most significant process parameters were maximum cushion thickness, cushion cut-out base radius, and cushion cut-out profile radius. The type of loading profile was found to be insignificant in all responses, but further investigation is required as the rate, and the thermal effects were not considered in the material modelling. Optimal process parameters were found to be a maximum cushion thickness of 3.01 mm, cushion cut-out base radius of 2.37 mm, cushion cut-out profile radius of 10 mm, and a "linear" loading profile. This yielded 0.50 mm, 0.00515 mm, 0.425 mm for peak shape deviation, thickness variation, and wrinkling, respectively.

A numerical study on indentation properties of cortical bone tissue: influence of anisotropy.

PURPOSE: The purpose of this study is to investigate the effect of anisotropy of cortical bone tissue on measurement of properties such as direction-dependent moduli and hardness. METHODS: An advanced three-dimensional finite element model of microindentation was developed. Different modelling schemes were considered to account for anisotropy of elastic or/and plastic regimes. The elastic anisotropic behaviour was modelled employing an elasticity tensor, and Hill's criteria were used to represent the direction-dependent post-yield behaviour. The Oliver-Pharr method was used in the data analysis. RESULTS: A decrease in the value of the transverse elasticity modulus resulted in the increased material's indentation modulus measured in the longitudinal direction and a decreased one in the transverse direction, while they were insensitive to the anisotropy in post-elastic regime. On the other hand, an increase in plastic anisotropy led to a decrease in measured hardness for both directions, but by a larger amount in the transverse one. The size effect phenomenon was found to be also sensitive to anisotropy. CONCLUSIONS: The undertaken analysis suggests that the Oliver-Pharr method is a useful tool for first-order approximations in the analysis of mechanical properties of anisotropic materials similar to cortical bone, but not necessarily for the materials with low hardening reserves in the plastic regime.

Penetration of cutting tool into cortical bone: experimental and numerical investigation of anisotropic mechanical behaviour.

An anisotropic mechanical behaviour of cortical bone and its intrinsic hierarchical microstructure act as protective mechanisms to prevent catastrophic failure due to natural loading conditions; however, they increase the extent of complexity of a penetration process in the case of orthopaedic surgery. Experimental results available in literature provide only limited information about processes in the vicinity of a tool-bone interaction zone. Also, available numerical models the bone-cutting process do not account for material anisotropy or the effect of damage mechanisms. In this study, both experimental and numerical studies were conducted to address these issues and to elucidate the effect of anisotropic mechanical behaviour of cortical bone tissue on penetration of a sharp cutting tool. First, a set of tool-penetration experiments was performed in directions parallel and perpendicular to bone axis. Also, these experiments included bone samples cut from four different cortices to evaluate the effect of spatial variability and material anisotropy on the penetration processes. Distinct deformation and damage mechanisms linked to different microstructure orientations were captured using a micro-lens high-speed camera. Then, a novel hybrid FE model employing a smoothed-particle-hydrodynamic domain embedded into a continuum FE one was developed based on the experimental configuration to characterise the anisotropic deformation and damage behaviour of cortical bone under a penetration process. The results of our study revealed a clear anisotropic material behaviour of the studied cortical bone tissue and the influence of the underlying microstructure. The proposed FE model reflected adequately the experimental results and demonstrated the need for the use of the anisotropic and damage material model to analyse cutting of the cortical-bone tissue.

Analysis of anisotropic viscoelastoplastic properties of cortical bone tissues.

Bone fractures affect the health of many people and have a significant social and economic effect. Often, bones fracture due to impacts, sudden falls or trauma. In order to numerically model the fracture of a cortical bone tissue caused by an impact it is important to know parameters characterising its viscoelastoplastic behaviour. These parameters should be measured for various orientations in a bone tissue to assess bone's anisotropy linked to its microstructure. So, the first part of this study was focused on quantification of elastic-plastic behaviour of cortical bone using specimens cut along different directions with regard to the bone axis-longitudinal (axial) and transverse. Due to pronounced non-linearity of the elastic-plastic behaviour of the tissue, cyclic loading-unloading uniaxial tension tests were performed to obtain the magnitudes of elastic moduli not only from the initial loading part of the cycle but also from its unloading part. Additional tests were performed with different deformation rates to study the bone's strain-rate sensitivity. The second part of this study covered creep and relaxation properties of cortical bone for two directions and four different anatomical positions-anterior, posterior, medial and lateral-to study the variability of bone's properties. Since viscoelastoplasticity of cortical bone affects its damping properties due to energy dissipation, the Dynamic Mechanical Analysis (DMA) technique was used in the last part of our study to obtain magnitudes of storage and loss moduli for various frequencies. Based on analysis of elastic-plastic behaviour of the bovine cortical bone tissue, it was found that magnitudes of the longitudinal Young's modulus for four cortical positions were in the range of 15-24 GPa, while the transversal modulus was lower--between 10 and 15 GPa. Axial strength for various anatomical positions was also higher than transversal strength with significant differences in magnitudes for those positions. Quantitative data obtained in creep and relaxation tests exhibited no significant position-specific differences. DMA results demonstrated relatively low energy-loss capability due to viscosity of bovine cortical bone that has a loss factor in the range of 0.035-0.1.