Porous Titanium Structures Research Articles

Properties of Additive-Manufactured Open Porous Titanium Structures for Patient-Specific Load-Bearing Implants

Additive manufacturing has been well established in many sectors, including the medical industry. For load-bearing bone implants, titanium and its alloys, such as Ti6Al4V, are widely used due to their high strength to weight ratio and osseointegrative properties. However, bone resorption and loosening of implants is related to the significantly higher stiffness of dense Ti6Al4V, leading to stress shielding. With the aging of population, there is an increasing need for orthopedic implants with a high success rate and a long implant life span. Besides that the treatment of non-healing segmental bone defects, where the self-repairing properties of bone tissue are not sufficient, is still a challenge. In both fields of application, patient-specific titanium implants combined with functionally graded porosity designed according to locally expected loads unlock new possibilities. Many studies underline the huge potential of the new design freedom to generate open porous structures and more personalized implants with enhanced mechanical properties that also integrate well with surrounding tissues. Integration of functionally graded open porosity into implants allows for the implant to more closely mimic the mechanical properties of human bone and its internal architecture. The results of this work represent the basis for developing complex porous titanium structures with various pore sizes and shapes to tailor structural mechanical properties and biological responses. Therefore, 3D porous structures with various pore sizes and shapes were designed and manufactured in Ti6Al4V using laser powder bed fusion (PBF-LB/M). Based on these structures, the correlation of pore size and shape with cell ingrowth, morphology, metabolic activity, and early markers for bone formation (ALP activity) was investigated in static cell cultures using the osteosarcoma cell line Saos-2. Mechanical properties, such as stiffness and compression strength, were investigated with compression testing. The present study concludes that cell morphology, metabolic activity, and ALP activity are widely independent of pore shape and size within the tested range of 400–700 µm pore size. Furthermore, the mechanical properties of the evaluated structures were in the range of cortical and trabecular bone. This opens the possibility to design mechanical properties with gradient porosity without decisively affecting biological responses.

Optimal Microstructure and Mechanical Properties of Open-Cell Porous Titanium Structures Produced by Selective Laser Melting

Optimal Microstructure and Mechanical Properties of Open-Cell Porous Titanium Structures Produced by Selective Laser Melting

Manufacturing of porous titanium using friction stir welding

In this research, a new cost-effective method is introduced for the first time to manufacture a porous titanium scaffold for implant applications. Initially, titanium and zinc plates were joined by Friction Stir Welding (FSW) method. Then, dezincification was done by immersion of the jointed samples in a hydrochloric acid solution (HCl). The results showed that after dealloying a porous titanium structure with open and interconnected morphology was successfully fabricated.

Osteoconductivity of Porous Titanium Structure on Implants in Osteoporosis

In compromised bone conditions such as osteoporosis, developments of the implant surface are necessary to secure the stability of implants. This study investigated the effect of the surface porous titanium structure (PS) on the osseointegration of implants in osteoporotic bone. Bilateral ovariectomy (OVX) was performed in 4 female beagle dogs to induce osteoporosis for 32 wk. Success of induction was based on the evaluation of bone mineral density by Hounsfield units (HU) in computed tomography images. Posterior teeth in both mandibles were extracted 1 wk after OVX, and a total of 30 implants (15 implants in each group) were placed after 32 wk of osteoporosis induction. The control group implant underwent resorbable blast media (RBM) surface treatment, whereas the test group underwent RBM surface treatment in the coronal two-thirds and a PS added to the apical 3-mm portion. HU values in the mandibular trabecular bone, lumbar, and femoral head significantly decreased 32 wk after OVX, confirming osteoporotic condition after induction. Resonance frequency analysis and removal torque test showed comparable values between the 2 groups at 4 wk after implant placement. The surface topography of the implant after removal showed hard tissue integration at the PS in the test group. Bone-to-implant contact length was greater in the apical portion of the test group, although statistical significance was not found between the groups. Interthread bone area in the apical portion of the test group showed a significant increase compared to the control group (control: 0.059 ± 0.041 mm2, test: 0.121 ± 0.060 mm2, P = 0.028) with the histological feature of bone ingrowth at the PS. The findings of the study demonstrated that the surface PS could improve osteoconductivity in the osteoporotic trabecular bone by bone ingrowth at the pore space, thereby enhancing the osseointegration and stability of the implants.

Topological Design of a Trabecular Bone Structure With Morphology and Mechanics Control for Additive Manufacturing

Porous metals are found to be suitable as orthopedic scaffolds. However, only limited control over the internal architecture can be achieved using conventional design methods. The architecture with porosity variation strategy mimicking natural bone is critical to gain favorable combination of mechanical and biological properties for orthopedic implants. In this regard, a topology optimization method with customized morphology and mechanical properties derived from the trabecular bone was proposed to design three-dimensional architectures with gradient porosity resembling the porous structure of bone. In particular, the elastic constants for the trabecular bone were better predicted when the bone volume fraction was supplemented with a three-dimensional structural parameter, i.e., degree of anisotropy. These constants were set as the optimization constrains for morphology control. Then the porous titanium structures were manufactured by selective laser melting technology (SLM). The physical characteristics, mechanical properties of the scaffolds were compared systematically. The experimental results revealed that the as-built samples with the proposed method lead to a good match of morphological accuracy and mechanical properties to that of the bone. It demonstrates that the proposed topology optimization method with controlled morphology and mechanical properties provides an efficient manner for the biomimetic design of orthopedic implants.

Investigation on preparation porous titanium through calciothermic reduction of porous TiO precursors

A route is present for preparing porous titanium scaffolds with open and interconnected pore morphology through calcium thermal in-situ reduction of TiO precursor. Titanium and dioxide titanium powders, with ammonium carbonate as the space holder, were used to prepare porous precursor whose main phase is TiO by a sintering process. Then calcium vapor was conduced to reduce the precursor and CaO was removed by leaching to obtain porous titanium structures. The morphology, pore structure, phase analysis of porous titanium precursor and porous titanium scaffolds were investigated by means of XRD, SEM and EDS. The porosity was observed by Archimedes method. By this route, the porous titanium with multi-gradient pore sizes ranging from a few microns to several hundred microns was formed. The porous titanium is of multi-gradient pore size distribution of 100 μm bigger, 10 μm∼100 μm and 10 μm smaller. The micro-pores on the pore walls increases connectivity between the macro-pores throughout the porous titanium interior. The porous titanium obtained by this method has a porosity of 50–65% and a titanium content more than 99%.

Titanium Scaffolds by Direct Ink Writing: Fabrication and Functionalization to Guide Osteoblast Behavior

Titanium (Ti) and Ti alloys have been used for decades for bone prostheses due to its mechanical reliability and good biocompatibility. However, the high stiffness of Ti implants and the lack of bioactivity are pending issues that should be improved to minimize implant failure. The stress shielding effect, a result of the stiffness mismatch between titanium and bone, can be reduced by introducing a tailored structural porosity in the implant. In this work, porous titanium structures were produced by direct ink writing (DIW), using a new Ti ink formulation containing a thermosensitive hydrogel. A thermal treatment was optimized to ensure the complete elimination of the binder before the sintering process, in order to avoid contamination of the titanium structures. The samples were sintered in argon atmosphere at 1200 °C, 1300 °C or 1400 °C, resulting in total porosities ranging between 72.3% and 77.7%. A correlation was found between the total porosity and the elastic modulus of the scaffolds. The stiffness and yield strength were similar to those of cancellous bone. The functionalization of the scaffold surface with a cell adhesion fibronectin recombinant fragment resulted in enhanced adhesion and spreading of osteoblastic-like cells, together with increased alkaline phosphatase expression and mineralization.

Enhancement of Bone Ingrowth into a Porous Titanium Structure to Improve Osseointegration of Dental Implants: A Pilot Study in the Canine Model.

A porous titanium structure was suggested to improve implant stability in the early healing period or in poor bone quality. This study investigated the effect of a porous structure on the osseointegration of dental implants. A total of 28 implants (14 implants in each group) were placed in the posterior mandibles of four beagle dogs at 3 months after extraction. The control group included machined surface implants with an external implant–abutment connection, whereas test group implants had a porous titanium structure added to the apical portion. Resonance frequency analysis (RFA); removal torque values (RTV); and surface topographic and histometric parameters including bone-to-implant contact length and ratio, inter-thread bone area and ratio in total, and the coronal and apical parts of the implants were measured after 4 weeks of healing. RTV showed a significant difference between the groups after 4 weeks of healing (p = 0.032), whereas no difference was observed in RFA. In the test group, surface topography showed bone tissue integrated into the porous structures. In the apical part of the test group, all the histometric parameters exhibited significant increases compared to the control group. Within the limitations of this study, enhanced bone growth into the porous structure was achieved, which consequently improved osseointegration of the implant.

In Vitro Bone Cell Behavior on Porous Titanium Samples: Influence of Porosity by Loose Sintering and Space Holder Techniques

A great variety of powder metallurgy techniques can produce biomimetic porous titanium structures with similar mechanical properties to host bone tissue. In this work, loose sintering and space holder techniques, two frequently used metallurgical techniques, are compared to evaluate the influences of porosity (content, size, morphology and wall roughness), mechanical properties (stiffness and yield strength) and in-vitro cellular responses (adhesion and proliferation of myoblasts and osteoblasts). These comparisons are made to achieve the best balance between biomechanical and bifunctional behavior of a partial porous implant for cortical bone replacement. Cell adhesion (filopodia presence) and spreading were promoted on both porous surfaces and fully dense substrates (non-porous control surfaces). Porous scaffold samples designed using 50 vol.% NaCl space holder technique had an improved bioactive response over those obtained with the loose sintering technique due to higher roughness and scaffold pore diameter. However, the presence of large and heterogeneous pores compromises the mechanical reliability of the implant. Considering both scenarios, the substrates obtained with 40 vol.% NH4HCO3 and pore size ranges between 100 and 200 μm provide a balanced optimization of size and strength to promote in-vitro osseointegration.

Synthesis and characterization of 3D-printed functionally graded porous titanium alloy

This study aims to 3D print titanium alloy constructs incorporating gradient of porosities, from the fully dense core to the porous outer surface. Gradient porous specimens were prepared using selective laser melting (SLM). Fully dense specimens fabricated by SLM were used as the control group. Characterization of samples was done using X-ray tomography, uniaxial compression testing, and optical and scanning electron microscopes. The biocompatibility of fabricated samples was investigated using human periodontal ligament stem cells via assessment of cell attachment, viability, and proliferation by direct and indirect assays. The data were analyzed using ANOVA and Tukey’s post hoc test. Characterization of constructs reveals interconnected gradient porosities and higher contact angle in porous samples. The introduction of porosity leads to a significant decrease in compression strength. However, Young’s modulus of the samples with gradient porosity was more similar to the natural bone modulus. The surface microstructure consists of loosely bonded spherical particles. Biocompatibility of the dense and porous samples is appropriate. Although the porosity size led to a reduced cell proliferation rate in the gradient sample, the extract of the gradient sample results in more cell proliferation than the dense sample’s extract. The study demonstrates that a biocompatible functionally graded porous titanium structure can be well fabricated by SLM, and this structure leads to a good match of Young’s modulus to that of the bone.

Enhanced fatigue characteristics of a topology-optimized porous titanium structure produced by selective laser melting

The fatigue properties are critical considerations for porous structures, and most of the existing porous materials have unsatisfactory performances due to a lack of structural optimization. This work shows that a topology-optimized structure fabricated by selective laser melting using commercial-purity titanium (CP-Ti) exhibits excellent fatigue properties with an ultra-high normalized fatigue life of ∼0.65 at 106 cycles and at a low density of 1.3 g/cm3. The main factors affecting fatigue, i.e., material properties and a porous structure were studied. Both the factors can affect the fatigue crack initiation time, thereby affecting the fatigue life. Because of twinning that occurred during the fatigue process, the porous CP-Ti samples exhibit a high plasticity. In addition, the fatigue crack propagation rate is significantly reduced because of the high plasticity of the CP-Ti material and the occurrence of fatigue crack deflection.

Recent advances in the development of methods for producing of porous titanium structures for medical applications

Recent advances in the development of methods for producing of porous titanium structures for medical applications

Desarrollo de Estructuras Porosas de Titanio para Implantes Biomédicos Obtenidas por Gel-casting y Sinterización

Este trabajo estudia un proceso para la fabricación de titanio poroso por pulvimetalúrgia, mediante la mezcla de TiH2, resina acrílica y un monómero líquido en distintas proporciones; así como el control del tamaño, forma y distribución de los poros para obtener implantes biomédicos osteointegrados con las características deseadas. Se presenta el estudio de las estructuras porosas mediante técnicas de microscopía óptica y procesado de imágenes por software y se discute sobre los resultados obtenidos del tamaño, forma y distribución de los poros para la correcta regeneración ósea.

Fatigue behavior of As-built selective laser melted titanium scaffolds with sheet-based gyroid microarchitecture for bone tissue engineering

Selective laser melting (SLM) has enabled the production of porous titanium structures with biological and mechanical properties that mimic bone for orthopedic applications. These porous structures have a reduced effective stiffness which leads to improved mechanotransduction between the implant and bone. Triply periodic minimal surfaces (TMPS), specifically the sheet-based gyroid structures, have improved compressive fatigue resistance due lack of stress concentrations. Sheet-based gyroid microarchitectures also have high surface area, permeability, and zero mean curvature. This study examines the effects of the gyroid microarchitectural design in parallel with SLM parameters on structure and function of as-built titanium alloy (Ti6Al4V ELI) scaffolds. Scaffold design was varied by varying unit cell size and wall thickness to produce scaffolds with porosity within the range of trabecular bone (50–90%). Manufacturer’s default and refined laser parameters were used to examine the effect of input energy density on mechanical properties. Scaffolds exhibited a stretching-dominated deformation behavior under both compressive and tensile loading, and porosity dependent stiffness and strength. Internal void defects were observed within the walls of the gyroids structure, serving as sites for crack initiation leading to failure. Refinement of laser parameters resulted in increased compressive and tensile fatigue behavior, particularly for thicker walled gyroid microarchitectures, while thinner walls showed no significant change. The observed properties of as-built gyroid sheet microarchitectures indicates that these structures have potential for use in bone engineering applications. Furthermore, these results highlight the importance of parallel design and processing optimization for complex sheet-based porous structures produced via SLM. Statement of SignificanceSelective laser melting (SLM) is an additive manufacturing technology which produces complex porous scaffolds for orthopedic applications. Titanium alloy scaffolds with novel sheet-based gyroid microarchitectures were produced via SLM and evaluated for mechanical performance including fatigue behavior. Gyroid structures are function based topologies have been hypothesized to be promising for tissue engineering scaffolds due to the high surface area to volume ratio, zero mean curvature, and high permeability. This paper presents the effects of scaffold design and processing parameters in parallel, a novel study in the field on bone tissue scaffolds produced via additive manufacturing. Additionally, the comparison of compressive and tensile behavior of scaffolds presented is important in characterizing behavior and failure mechanisms of porous metals which undergo complex loading in orthopedic applications.

Multi-axial fatigue behaviour of titanium periodic cellular structures produced by Selective Laser Melting (SLM)

Additive manufacturing techniques such as selective laser melting (SLM) allow for manufacturing periodic porous titanium structures having complex geometry. The mechanical properties of these structures with different elementary cell (ECs) designs have been already studied in literature. However, their fatigue behaviour is not yet well understood. This work aims at proposing a numerical approach to predict the periodic cellular structures fatigue behaviour under multiaxial loadings. The approach is based on an explicit description of the EC combined to an extreme statistical analysis making use of a fatigue indicator parameter to investigate (and compare) different EC configurations. On the other hand, the numerical model relies on the use of a general numerical homogenisation scheme to properly apply the multi-axial loading conditions to the EC at the mesoscopic scale. Results show that lattice fatigue strength is strongly affected by the relative density as well as by the geometrical features of the EC.

Preparation and Properties of Titanium Obtained by Spark Plasma Sintering of a Ti Powder⁻Fiber Mixture.

Porous titanium is a functional structural material with certain porosity, which is prepared from titanium powder and titanium fiber. In order to study the porosity, phase structure, microstructure, sintering mechanism and mechanical properties of porous titanium obtained by spark plasma sintering of a Ti powder–fiber mixture at different sintering temperatures, a spherical titanium powder (D50 of 160 μm) was prepared via plasma rotating electrode processing, and titanium fiber (average wire diameter of fiber of 110 μm) was prepared by drawing, and they were mixed as raw materials according to different mass ratios. Porous titanium with a fiber–powder composite porous structure was prepared by spark plasma sintering at sintering temperatures of 800 °C, 900 °C and 1000 °C under a sintering pressure of 20 MPa. The results showed that there were no new phases occurring in porous titanium with porosity of 1.24–24.6% after sintering. Titanium fiber and titanium powder were sintered using powder/powder, powder/fiber and fiber/fiber regimes to form composite pore structures. The mass transfer mechanism of the sintered neck was a diffusion-dominated material migration mechanism during sintering. At higher sintering temperatures, the grain size was larger, and the fiber (800 °C; 10–20 μm) was finer than the powder (800 °C; 10–92 μm). The stress–strain curve of porous titanium showed no obvious yield point, and the compressive strength was higher at higher sintering temperatures. The results of this paper can provide data reference for the preparation of porous titanium obtained by spark plasma sintering of a Ti powder–fiber mixture.

Preparation of porous titanium by direct in-situ reduction of titanium sesquioxide

A new process to fabricate porous titanium by calcium vapor in-situ reduction of titanium sespuioxide was presented in this paper. The mixture of Ti2O3 and CaCl2 powders was preformed and reduced by calcium vapor. The porous titanium structure was obtained after leaching reduction products with hydrochloric acid and deionized water. The pore structure, morphology, composition of reduction products were investigated by SEM-EDS and XRD. The influence of different contents of anhydrous calcium chloride on porosity was discussed. The results show metallic titanium products with two types of pore structures and vacuum sintering treatment strengthened effectively connection between titanium particles. The porosity of porous titanium samples was 62%–82% and more than 90% of pores are open-pores.

Effect of CaCl2 on Microstructure of Calciothermic Reduction Products of Ti2O3 to Prepare Porous Titanium

The compound CaCl2 plays a significant role in the process of direct calciothermic reduction of Ti2O3 to prepare porous titanium. In this paper, the effect of CaCl2 on reduction products by calciothermic reduction of Ti2O3 was investigated. Results show that the distribution of CaCl2 in reduction preform influences particle size and morphology differences in reduction products both on the surface and the inside. The CaCl2 is transferred to the surface of the Ti2O3 preform due to its volatilization before and throughout reduction. The content of CaCl2 in the surface zone of Ti2O3 preform is significantly higher than that in the interior during the reduction process, contributing to the formation of large Ti particles with a smooth shape on the surface, and small Ti particles with inherited morphology of Ti2O3 inside. More CaCl2 causes the aggregation of Ti particles to form large Ti particles which are advantageous as they connect and form a more solid porous titanium structure. The presence of a small amount of CaCl2 in the interior also results in the coexistence of small Ti and CaO particles, forming a loose structure with uniform distribution.

Influence of Cobalt and Molybdenum Additives on the Structure and Shape Memory Parameters of Reaction-Sintered Porous Nickel Titanium Alloys

We have studied the structure and properties of porous nickel titanium (TiNi) alloys obtained upon reaction sintering of Ti and Ni powders with Co and Mo additives. It is established that Co and Mo doping additives retain the compaction of Ni powder achieved at the initial stage of sintering. The maximum deformation of porous samples loaded in the austenite state was observed upon adding Co, while the addition of Mo resulted in minimum deformation. The addition of Co leads to single-stage martensitic transformation in TiNi phase, while the addition of Mo leads to the two-stage transformation that is more homogeneous over the volume. Both Co and Mo additives lead to increase in the maximum accumulated strain due to the formation of favorably oriented stress-induced martensite and reoriented quench-induced martensite.

STUDY OF REPAROTIVNYH PROPERTIES OF CELLULAR STRUCTURES MADE OF TITANIUM IN THE EXPERIMENT

Aim. Using metallography to determine the architectonics wire mesh implant made by the method of stereolithography. In the experiment to compare the structure of different materials and their degree of fixation in the bone (wire mesh of titanium, Plekon and porous titanium). Material and methods. The paper presents the simulation results, fabrication of the implants, which perform cellular structure (cell Wigner-Seitz). When applied three-dimensional modeling system, and in the production – technology stereolithography. The results of the research porous implants from titanium using a universal metallographic microscope Altami MET-5D by increasing from 50Х up to 200X. Results. It was found that the surface of the walls are not smooth, but bumpy due to the microscopic depressions and protrusions of the metal. The cone micro canals are clearly seen, scattered that some of them are cross-cutting, others end blindly. In the microchannel jumpers implant founded sprouted connective tissue filling all the space, the density is not inferior to the connective tissue located in the cells. Established that the fourth degree of fixation of mesh implants was identified in 55.6% of the animals of porous Placona-M - y 28.6% of the subjects, of porous titanium – 41,6%, indicating a high reparative properties of cellular structures. Conclusions. The Jumper forming cells of the implant structure have a structure of porous titanium with reparative properties. IV the degree of fixation of mesh implants was identified in 55.6% of animals, indicating a high reparative properties of cellular structures.