Static Compressive Behavior and Failure Mechanism of Tantalum Scaffolds with Optimized Periodic Lattice Fabricated by Laser-Based Additive Manufacturing.

Porous tantalum (Ta) scaffolds have been extensively used in the clinic for reconstructing bone tissues owing to their outstanding corrosion resistance, biocompatibility, osteointegration, osteoconductivity, and mechanical properties. Additive manufacturing (AM) has an advantage in fabricating patient-specific and anatomical-shape-matching bone implants with controllable and well-designed porous architectures through tissue engineering. The sharp angles of strut joints in porous structures can cause stress concentration, reducing mechanical properties of the structures. In this study, porous Ta scaffolds comprising rhombic dodecahedron lattice unit cells with optimized node radius and porosities of 65%, 75%, and 85% were designed and fabricated by AM. The porous architecture and microstructure were characterized. The compressive behavior and failure mechanism of the material were explored through experimental compression tests and finite element analysis (FEA). Morphological evaluations revealed that the Ta scaffolds are fully interconnected, and the struts are dense. No processing defects and fractures were observed on the surface of struts. The scaffolds exhibited compressive yield strength of 5.8-32.3 MPa and elastic modulus of 0.6-4.5 GPa, comparable to those of human cancellous and trabecular bone. The compressive stress-strain curves of all samples show ductile deformation behavior accompanied by a smooth plateau region. The AM-fabricated rhombic dodecahedron lattice Ta scaffolds exhibited excellent ductility and mechanical reliability and plastic failure due to bending deformation under compressive loading. Deformation and factures primarily occurred at the junctions of the rhombus-arranged struts in the longitudinal section. Moreover, the struts in the middle of the scaffolds underwent a larger deformation than those close to the loading ends. FEA revealed a smooth stress distribution on the rhombic dodecahedron lattice structure with optimized node radius and stress concentration at the junctions of rhombus-arranged struts in the longitudinal section, which is in good agreement with the experimental results. Thus, the AM-fabricated Ta scaffolds with optimized node radius are promising alternatives for bone repair and regeneration.

Optimize the pore size-pore distribution-pore geometry-porosity of 3D-printed porous tantalum to obtain optimal critical bone defect repair capability.

The treatment and reconstruction of large or critical size bone defects is a challenging clinical problem. Additive manufacturing breaks the technical difficulties of preparing complex conformation and anatomically matched personalized porous tantalum implants, but the ideal pore structure for 3D-printed porous tantalum in critical bone defect repair applications remains unclear. Guiding appropriate bone tissue regeneration by regulating proper pore size-pore distribution-pore geometry-porosity is a challenge for its fabrication and application. We fabricated porous tantalum (PTa) scaffolds with six different combinations of pore structures using powder bed laser melting (L-PBF) technology. In vitro biological experiments were conducted to systematically investigate the effects of pore structure characteristics on osteoblast behaviors, showing that the bionic trabecular structure with both large and small poress facilitated cell permeation, proliferation and differentiation compared to the cubic structure with uniform pore sizes. The osteogenesis of PTa with different porosity of trabecular structures was further investigated by a rabbit condyle critical bone defect model. Synthetically, T70% up-regulated the expression of osteogenesis-related genes (ALP, COLI, OCN, RUNX-2) and showed the highest bone ingrowth area and bone contact rate in vivo after 16 weeks, with the best potential for critical bone defect repair. Our results suggested that the bionic trabecular structure with a pore size distribution of 200-1200 µm, an average pore size of 700 µm, and a porosity of 70 % is the best choice for repairing critical bone defects, which is expected to guide the clinical application of clinical 3D-printed PTa scaffolds.

Influence of porosity on osteogenesis, bone growth and osteointegration in trabecular tantalum scaffolds fabricated by additive manufacturing.

Porous tantalum implants are a class of materials commonly used in clinical practice to repair bone defects. However, the cumbersome and problematic preparation procedure have limited their widespread application. Additive manufacturing has revolutionized the design and process of orthopedic implants, but the pore architecture feature of porous tantalum scaffolds prepared from additive materials for optimal osseointegration are unclear, particularly the influence of porosity. We prepared trabecular bone-mimicking tantalum scaffolds with three different porosities (60%, 70% and 80%) using the laser powder bed fusing technique to examine and compare the effects of adhesion, proliferation and osteogenic differentiation capacity of rat mesenchymal stem cells on the scaffolds in vitro. The in vivo bone ingrowth and osseointegration effects of each scaffold were analyzed in a rat femoral bone defect model. Three porous tantalum scaffolds were successfully prepared and characterized. In vitro studies showed that scaffolds with 70% and 80% porosity had a better ability to osteogenic proliferation and differentiation than scaffolds with 60% porosity. In vivo studies further confirmed that tantalum scaffolds with the 70% and 80% porosity had a better ability for bone ingrowh than the scaffold with 60% porosity. As for osseointegration, more bone was bound to the material in the scaffold with 70% porosity, suggesting that the 3D printed trabecular tantalum scaffold with 70% porosity could be the optimal choice for subsequent implant design, which we will further confirm in a large animal preclinical model for better clinical use.

Static Compressive Behavior and Material Failure Mechanism of Trabecular Tantalum Scaffolds Fabricated by Laser Powder Bed Fusion-based Additive Manufacturing.

Additively manufactured trabecular tantalum (Ta) scaffolds are promising bone repair materials for load-bearing applications due to their good pore interconnectivity. However, a thorough mechanical behavior evaluation is required before conducting animal studies and clinical research using these scaffolds. In this study, we revealed the compressive mechanical behavior and material failure mechanism of trabecular tantalum scaffolds by compression testing, finite element analysis (FEA), and scanning electron microscopy (SEM). Trabecular tantalum scaffolds with porosities of 65%, 75%, and 85% were fabricated by laser powder bed fusion-based additive manufacturing. Porosity has a significant effect on their compressive mechanical properties. As the porosity decreased from 85% to 65%, the compressive yield strength and elastic modulus increased from 11.9 MPa to 35.7 MPa and 1.1 GPa to 3.0 GPa, respectively. Compression testing results indicate that trabecular tantalum scaffolds demonstrate ductile deformation and excellent mechanical reliability. No macroscopic cracks were found when they were subjected to strain up to 50%. SEM observations showed that material failure results from tantalum strut deformation and fracture. Most microcracks occurred at conjunctions, whereas few of them appear on the struts. FEA-generated compressive stress distribution and material deformation were consistent with experimental results. Stress concentrates at strut conjunctions and vertical struts, where fractures occur during compression testing, indicating that the load-bearing capability of trabecular tantalum scaffolds can be enhanced by strengthening strut conjunctions and vertical struts. Therefore, additively manufactured trabecular tantalum scaffolds can be used in bone tissue reconstruction applications.

Fatigue behaviour and biocompatibility of additively manufactured bioactive tantalum graded lattice structures for load-bearing orthopaedic applications.

Laser powder bed fusion (LPBF) additive manufacturing of pure tantalum and their graded lattice structures was systematically investigated, with emphasis on their microstructure evolution, phase formation, surface energy and biological properties in comparison with conventionally forged pure Ta. The LPBF fabricated Ta (LPBF-Ta) exhibited lower contact angles and higher surface energy than the forged-Ta which indicated the better wettability of the LPBF-Ta. The adhesion and proliferation of rat bone marrow stromal cells (rBMSCs) were also enhanced for the LPBF-Ta when compared to forged-Ta. Three different Ta graded gyroid lattice structures (i.e., uniform structure, Y-gradient structure, Z-gradient structure) were designed and fabricated using the same optimised LPBF parameters. Y-gradient structures exhibited the best plateau stress and compressive modulus among three different graded structures due to the maximum local volume fraction on the fracture plane. In fatigue response, Y-gradient outperformed the other two gyroid structures under varying stresses. In terms of cell culture response, the uniform structures performed the best biocompatibility due to its suitable pore size for cell adhesion and growth. This study provides new and in-depth insights into the LPBF additive manufacturing of pure Ta graded lattice structures with desired fatigue and biological properties for load-bearing orthopaedic applications.