Nanofinishing of DED topologically optimized fixation plates with H-ECMR finishing

Abstract

ABSTRACT Fixation plates are crucial to ensure the fracture site remains stable and prevent any movement that could widen the gap between broken bones, ultimately promoting the healing process of the bone. Topological optimization is a solution to increase the strength-to-mass ratio and produce lightweight metal implants with less stiffness to reduce stress shielding. Laser-Directed Energy Deposition (L-DED) is a 3d printing method to fabricate objects with near-net shapes. However, the manufactured implants’ surface quality is still a major issue and further leads to an increase in the release of metal ions, which can cause inflammation and infection and lead to screw loosening. The current study aims to design and develop the topologically optimized fixation plate to reduce stress shielding further fabricated and polished by the L-DED and H-ECMR super polishing method, respectively. Herein, the H-ECMR super finishing method reduced the Ra value of the manufactured parts to 29.26 nm.