3D-printed Ti6Al4V Research Articles

Integration of a Three-Dimensional-Printed Titanium Implant in Human Tissues: Case Study

A titanium alloy implant of appropriate pore size can potentially enhance osseointegration and soft tissue integration. However, the human clinical application of such implants has not been reported. Here, we present a case of limb salvage surgery for a bone tumor using customized three-dimensional (3D)-printed Ti6Al4V radius and ulna implants. The patient presented with local recurrence at the proximal junction of the ulna and underwent a re-wide excision. Single forearm bone surgery was performed using another 3D-printed implant after resection of the recurrent tumor with an ulnar implant. Host osseointegration and soft tissue integration of the retrieved implant were quantified through histological evaluation. The total tissue integration rates of the implant at the proximal and distal bone junctions were 45.96% and 15.03%, respectively. The mesh structure enhanced bone integration by up to 10.81% in the proximal and by up to 8.91% in the distal bone junction. Furthermore, the soft tissue adhesion rates of the implant shaft were 59.50% and 50.26% in the axial and longitudinal cuts, respectively. No area was left unoccupied throughout the shaft of the implant. Overall, these results indicate that the 3D-printed Ti6Al4V titanium alloy implant with a rough surface has considerable tissue integration ability.

A comparative study of the osteogenic performance between the hierarchical micro/submicro-textured 3D-printed Ti6Al4V surface and the SLA surface

Three-dimensional (3D) printed titanium and its alloys have broad application prospect in the field of biomedical implant materials, although the biological performance of the original surface should be improved. Learning from the development experience of conventional titanium implants, to construct a hierarchical hybrid topological surface is the future direction of efforts. Since the original 3D-printed (3D hereafter) Ti6Al4V surface inherently has micron-scale features, in the present study, we introduced submicron-scale pits on the original surface by acid etching to obtain a hierarchical micro/submicro-textured surface. The characteristic and biological performance of the 3D-printed and acid-etched (3DA hereafter) surface were evaluated in vitro and in vivo, compared with the conventional sandblasted, large-grit, acid-etched (SLA hereafter) surface. Our results suggested the adhesion, proliferation and osteogenic differentiation of bone marrow derived mesenchymal stromal cells (BMSCs), as well as the in vivo osseointegration on 3DA surfaces were significantly improved. However, the overall osteogenic performance of the 3DA surface was not as good as the conventional SLA surface.

Improved osseointegration with rhBMP-2 intraoperatively loaded in a specifically designed 3D-printed porous Ti6Al4V vertebral implant.

Three-dimensional (3D)-printed porous Ti6Al4V implants are commonly used for reconstructing bone defects in the treatment of orthopaedic diseases owing to their excellent osteoconduction. However, to achieve improved therapeutic outcomes, the osteoinduction of these implants requires further improvement. The aim of this study was to investigate the combined use of recombinant human BMP-2 (rhBMP-2) with a 3D-printed artificial vertebral implant (3D-AVI) to improve the osteoinduction. Eight male Small Tail Han sheep underwent cervical corpectomy, and 3D-AVIs with or without loaded rhBMP-2 in cavities designed at the center were implanted to treat the cervical defect. Radiographic, micro-computed tomography, fluorescence labelling, and histological examination revealed that the osseointegration efficiency of the rhBMP-2 group was significantly higher than that of the blank control group. The biomechanical test results suggested that rhBMP-2 reduced the range of motion of the cervical spine and provided a more stable implant. Fluorescence observations revealed that the bone tissue grew from the periphery to the center of the 3D-AVIs, first growing into the pore space and then interlocking with the Ti6Al4V implant surface. Therefore, we successfully improved osseointegration of the 3D-AVI by loading rhBMP-2 into the cavity designed at the center of the Ti6Al4V implant, realizing earlier and more stable fixation of implants postoperatively in a simple manner. These benefits of rhBMP-2 are expected to expand the application range and reliability of 3D-printed porous Ti6Al4V implants and improve their therapeutic efficacy.

Direct ink writing of porous titanium (Ti6Al4V) lattice structures.

Ti6Al4V components, for biomedical and aerospace sectors, are receiving a great interest especially after the advent of additive manufacturing technologies. The most used techniques are Selective Laser Sintering (SLS), Selective Laser Melting (SLM) and Electron Beam Melting (EBM). In the current research, we developed 3D-printed Ti6Al4V scaffolds by Direct Ink Writing (DIW) technology. Appropriate ink formulations, based on water-titanium powder suspensions, were achieved by controlling the rheological properties of the developed inks. After printing process, and drying, the printed components were sintered at 1400 °C under high vacuum for 3 h. Highly porous titanium scaffolds (with porosity up to 65 vol%) were produced and different geometries were printed. The influence of the porosity on the morphology, compression strength and biocompatibility of the scaffolds was investigated.

Integrating 3D Printing and Biomimetic Mineralization for Personalized Enhanced Osteogenesis, Angiogenesis, and Osteointegration.

Titanium (Ti) alloy implants can repair bone defects at load-bearing sites. However, they mechanically mismatch with the natural bone and lack customized adaption with the irregularly major-sized load-bearing bone defects, resulting in the failure of implant fixation. Mineralized collagen (MC), a building block in bone, can induce angiogenesis and osteogenesis, and 3D printing technology can be employed to prepare scaffolds with an overall shape customized to the bone defect. Hence, we induced the formation of MC, made of hydroxyapatite (HAp) nanocrystals and collagen fibers, in 3D-printed porous Ti6Al4V (PT) scaffolds through in situ biomimetic mineralization. The resultant MC/PT scaffolds exhibited a bone-like Young's modulus and were customized to the anatomical contour of actual bone defects of rabbit model. We found that the biocompatibility and osteogenic differentiation are best when the mass ratio between HAp nanocrystals and collagen fibers is 1 in MC. We then implanted the MC/PT scaffolds into the customized radius defect rabbit model and found that the MC/PT scaffolds significantly improved the vascularized bone tissue formation and integration between new bone and the implants. Therefore, a combination of 3D printing and biomimetic mineralization could lead to customized 3D PT scaffolds for enhanced angiogenesis, osteogenesis, and osteointegration. Such scaffolds represent novel patient-specific implants for precisely repairing irregularmajor-sized load-bearing bone defects.

3D Culture of Bone Marrow-Derived Mesenchymal Stem Cells (BMSCs) Could Improve Bone Regeneration in 3D-Printed Porous Ti6Al4V Scaffolds.

Mandibular bone defect reconstruction is an urgent challenge due to the requirements for daily eating and facial aesthetics. Three-dimensional- (3D-) printed titanium (Ti) scaffolds could provide patient-specific implants for bone defects. Appropriate load-bearing properties are also required during bone reconstruction, which makes them potential candidates for mandibular bone defect reconstruction implants. However, in clinical practice, the insufficient osteogenesis of the scaffolds needs to be further improved. In this study, we first encapsulated bone marrow-derived mesenchymal stem cells (BMSCs) into Matrigel. Subsequently, the BMSC-containing Matrigels were infiltrated into porous Ti6Al4V scaffolds. The Matrigels in the scaffolds provided a 3D culture environment for the BMSCs, which was important for osteoblast differentiation and new bone formation. Our results showed that rats with a full thickness of critical mandibular defects treated with Matrigel-infiltrated Ti6Al4V scaffolds exhibited better new bone formation than rats with local BMSC injection or Matrigel-treated defects. Our data suggest that Matrigel is able to create a more favorable 3D microenvironment for BMSCs, and Matrigel containing infiltrated BMSCs may be a promising method for enhancing the bone formation properties of 3D-printed Ti6Al4V scaffolds. We suggest that this approach provides an opportunity to further improve the efficiency of stem cell therapy for the treatment of mandibular bone defects.

The effect of 3D-printed Ti6Al4V scaffolds with various macropore structures on osteointegration and osteogenesis: A biomechanical evaluation

A properly designed porous scaffold can accelerate the osseointegration process, and the use of computer-aided design (CAD) and additive manufacturing (AM) techniques has the potential to improve the traditional porous scaffold approach. In this study, we evaluate the effect of porous Ti6Al4V (Ti) with different pore structures on osteointegration and osteogenesis. Porous Ti scaffolds with different pore structures based on four commercially available implants were designed and manufactured by CAD and selective laser melting (SLM). Micro-CT showed that SLM was able to produce Ti scaffolds with different pore structures. The mechanical properties evaluated by finite element analysis and compression tests indicated that the four porous scaffolds in our study were mechanically adapted, despite their different mechanical properties. Then, we used 3D-printed porous discs to culture human bone marrow mesenchymal stem cells (hBMMSCs), the main seed cells of bone tissue engineering. The results showed no significant difference among the four groups in cell morphology, viability and proliferation. In addition, four groups showed a comparable mineralization ability even though Ti-g had a higher alkaline phosphatase activity (ALP). In vivo tests in a rabbit model showed that all four groups were suitable for new bone ingrowth and integration. These findings indicate that the four different pore structures in the Ti scaffolds provided good osteointegration and osteogenesis.

Influence of simultaneous addition of carbon nanotubes and calcium phosphate on wear resistance of 3D-printed Ti6Al4V

Abstract

Hydroxyapatite Nanoparticle-Coated 3D-Printed Porous Ti6Al4V and CoCrMo Alloy Scaffolds and Their Biocompatibility to Human Osteoblasts.

Hydroxyapatite nanoparticles were prepared by hydrothermal method using calcium nitrate and phosphoric acid as precursors and ammonia aqueous solution as a pH value adjustor. The 3D-printed porous Ti6Al4V and CoCrMo alloy scaffolds were effectively coated with hydroxyapatite nanoparticles in the hydrothermal synthesis process by deposition method. Coating hydroxyapatite nanoparticles on the implant surfaces increased their biocompatibility and bioactivity. HAP-deposited Ti6Al4V or HAP-deposited CoCrMo scaffold induced no statistical increase in terms of apoptosis in hFOB1.19 cells compared with bare Ti6Al4V or bare CoCrMo. Interestingly, HAP coating groups presented CCK-8 values compared with bare groups suggesting that HAP could enhance cell proliferation.

Synthesis and Evaluation of A High Precision 3D-Printed Ti6Al4V Compliant Parallel Manipulator

A novel 3D printed compliant parallel manipulator (CPM) with θX − θX − Z motions is presented in this paper. This CPM is synthesized using the beam-based method, a new structural optimization approach, to achieve optimized stiffness properties with targeted dynamic behavior. The CPM performs high non-actuating stiffness based on the predicted stiffness ratios of about 3600 for translations and 570 for rotations, while the dynamic response is fast with the targeted first resonant mode of 100Hz. A prototype of the synthesized CPM is fabricated using the electron beam melting (EBM) technology with Ti6Al4V material. Driven by three voice-coil (VC) motors, the CPM demonstrated a positioning resolution of 50nm along the Z axis and an angular resolution of ~0.3 “about the X and Y axes, the positioning accuracy is also good with the measured values of ±25.2nm and ±0.17” for the translation and rotations respectively. Experimental investigation also shows that this large workspace CPM has a first resonant mode of 98Hz and the stiffness behavior matches the prediction with the highest deviation of 11.2%. Most importantly, the full workspace of 10° × 10° × 7mm of the proposed CPM can be achieved, that demonstrates 3D printed compliant mechanisms can perform large elastic deformation. The obtained results show that CPMs printed by EBM technology have predictable mechanical characteristics and are applicable in precise positioning systems.

Incorporating simvastatin/poloxamer 407 hydrogel into 3D-printed porous Ti6Al4V scaffolds for the promotion of angiogenesis, osseointegration and bone ingrowth

Three-dimensional porous titanium alloys printed via electron beam melting have low stiffness similar to that of cortical bone and are promising scaffolds for orthopedic applications. However, the bio-inert nature of titanium alloy is poorly compatible with bone ingrowth. We previously observed that simvastatin/poloxamer 407 thermosensitive hydrogel induces endogenous angiogenic/osteogenic growth factors and promotes angiogenesis and osteogenesis, but the mechanical properties of this hydrogel are poor. The purpose of this study was to construct 3D-printed porous titanium scaffolds (pTi scaffolds) filled with simvastatin/hydrogel and evaluate the effects of this composite on osseointegration, bone ingrowth and neovascularization using a tibial defect rabbit model. Four and eight weeks after implantation, the bone volume, bone mineral density, mineral apposition rate, and push-in maximum force of the pTi scaffolds filled with simvastatin/hydrogel were significantly higher than those without simvastatin (p < 0.05). Moreover, filling with simvastatin/hydrogel significantly enhanced vascularization in and around the pTi scaffolds, and a significant correlation was observed between the volume of new bone and neovascularization (p < 0.01). In conclusion, incorporating simvastatin/poloxamer 407 hydrogel into pTi scaffolds significantly improves neovascularization, osseointegration and bone ingrowth.