A Metallographic Review of 3D Printing/Additive Manufacturing of Metal and Alloy Products and Components

Forged to heal: The role of metallic cellular solids in bone tissue engineering

Metallic cellular solids, made of biocompatible alloys like titanium, stainless steel, or cobalt-chromium, have gained attention for their mechanical strength, reliability, and biocompatibility. These three-dimensional structures provide support and aid tissue regeneration in orthopedic implants, cardiovascular stents, and other tissue engineering cellular solids. The design and material chemistry of metallic cellular solids play crucial roles in their performance: factors such as porosity, pore size, and surface roughness influence nutrient transport, cell attachment, and mechanical stability, while their microstructure imparts strength, durability and flexibility. Various techniques, including additive manufacturing and conventional fabrication methods, are utilized for producing metallic biomedical cellular solids, each offering distinct advantages and drawbacks that must be considered for optimal design and manufacturing. The combination of mechanical properties and biocompatibility makes metallic cellular solids superior to their ceramic and polymeric counterparts in most load bearing applications, in particular under cyclic fatigue conditions, and more in general in application that require long term reliability. Although challenges remain, such as reducing the production times and the associated costs or increasing the array of available materials, metallic cellular solids showed excellent long-term reliability, with high survival rates even in long term follow-ups.

Flexible Ceramic Film Sensors for Free-Form Devices

Recent technological innovations, such as material printing techniques and surface functionalization, have significantly accelerated the development of new free-form sensors for next-generation flexible, wearable, and three-dimensional electronic devices. Ceramic film sensors, in particular, are in high demand for the production of reliable flexible devices. Various ceramic films can now be formed on plastic substrates through the development of low temperature fabrication processes for ceramic films, such as photocrystallization and transferring methods. Among flexible sensors, strain sensors for precise motion detection and photodetectors for biomonitoring have seen the most research development, but other fundamental sensors for temperature and humidity have also begun to grow. Recently, flexible gas and electrochemical sensors have attracted a lot of attention from a new real-time monitoring application that uses human breath and perspiration to accurately diagnose presymptomatic states. The development of a low-temperature fabrication process of ceramic film sensors and related components will complete the chemically stable and reliable free-form sensing devices by satisfying the demands that can only be addressed by flexible metal and organic components.

3D printed nickel catalytic static mixers made by corrosive chemical treatment for use in continuous flow hydrogenation

Catalytic static mixers, 3D printed from nickel alloys, were treated with etching or leaching solutions to activate their surfaces for use in hydrogenation of alkenes, aldehydes and nitro-groups.

3D/4D Printing of Polymers: Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA)

Additive manufacturing (AM) or 3D printing is a digital manufacturing process and offers virtually limitless opportunities to develop structures/objects by tailoring material composition, processing conditions, and geometry technically at every point in an object. In this review, we present three different early adopted, however, widely used, polymer-based 3D printing processes; fused deposition modelling (FDM), selective laser sintering (SLS), and stereolithography (SLA) to create polymeric parts. The main aim of this review is to offer a comparative overview by correlating polymer material-process-properties for three different 3D printing techniques. Moreover, the advanced material-process requirements towards 4D printing via these print methods taking an example of magneto-active polymers is covered. Overall, this review highlights different aspects of these printing methods and serves as a guide to select a suitable print material and 3D print technique for the targeted polymeric material-based applications and also discusses the implementation practices towards 4D printing of polymer-based systems with a current state-of-the-art approach.

Effect of build direction dependent grain structure on fatigue crack growth of biomedical Co-29Cr-6Mo alloy processed by laser powder bed fusion

Biomedical Co-29Cr-6Mo alloy is one of the alloys that are suitable for laser powder bed fusion (LPBF) additive manufacturing and as an implant material is often used in situations of critical and cyclic loading. Thus, fatigue crack growth (FCG) behaviour and resistance of the alloy processed by LPBF are an important consideration for dental and orthopaedic applications. In this study, FCG testing has been conducted to evaluate how build direction (BD) dependent grain/cell structure in relation to crack growth direction (CD), either CD⊥BD or CD//BD, affects FCG behaviour. It has been found that the threshold stress intensity factor (ΔK_Th) value is significantly higher and the values of c and m in Paris equation are slightly lower for CD//BD samples than the values for CD⊥BD samples, respectively. Failure analysis has revealed that the effects of the commonly known defect, lack of fusion, on both ΔK_Th and FCG rate are weak. It has been identified that crack has mainly propagated in a transgranular and transcellular manner, consistent with the observation of the crack path being more torturous and with the higher crack growth resistance determined in CD//BD samples than in CD⊥BD samples. This will be further discussed linking the difference in the size of crack segment, which is BD and thus grain/cell length dependent, to the roughness-induced crack closure mechanism.

Mechanical properties and in vitro cytocompatibility of dense and porous Ti-6Al-4V ELI manufactured by selective laser melting technology for biomedical applications

The Ti-6Al-4V alloy is the most common biomaterial used for bone replacements and reconstructions. Despite its advantages, the Ti-6Al-4V has a high stiffness that can cause stress-shielding. In this work, we demonstrated that the selective laser melting (SLM) technology could be used to fabricate porosity in Ti-6Al-4V extra low interstitial (ELI) to reduce its stiffness while improving cell adhesion and proliferation. With a porosity of 14.04%, the elastic modulus of the porous Ti-6Al-4V ELI was reduced to 80 GPa. The compressive stress and the 3-point-bending flexural tests revealed that the porous Ti-6Al-4V ELI possessed a brittle characteristic. The additional pores within the beams of the lattice structures of porous Ti-6Al-4V ELI increased its surface arithmetic average roughness, R_a = 3.94 μm. The in vitro cytocompatibility test showed that the SLM printing process and the post-processes did not cause any toxicity in the MC3T3-E1 cells. The in vitro cell proliferation test also showed that the porous Ti-6Al-4V ELI increased the proliferation rate of osteogenic induced MC3T3-E1 cells on Day 7. The findings from this study would provide engineers and researchers with both the mechanical information and biological understanding of SLM printed porous Ti-6Al-4V ELI, and SLM printed dense Ti-6Al-4V ELI towards biomedical applications.

In Situ SEM Study of the Micro-Mechanical Behaviour of 3D-Printed Aluminium Alloy

Currently, 3D-printed aluminium alloy fabrications made by selective laser melting (SLM) offer a promising route for the production of small series of custom-designed support brackets and heat exchangers with complex geometry and shape and miniature size. Alloy composition and printing parameters need to be optimised to mitigate fabrication defects (pores and microcracks) and enhance the parts’ performance. The deformation response needs to be studied with adequate characterisation techniques at relevant dimensional scale, capturing the peculiarities of micro-mechanical behaviour relevant to the particular article and specimen dimensions. Purposefully designed Al-Si-Mg 3D-printable RS-333 alloy was investigated with a number of microscopy techniques, including in situ mechanical testing with a Deben Microtest 1-kN stage integrated and synchronised with Tescan Vega3 SEM to acquire high-resolution image datasets for digital image correlation (DIC) analysis. Dog bone specimens were 3D-printed in different orientations of gauge zone cross-section with respect to the fast laser beam scanning and growth directions. This corresponded to the varying local conditions of metal solidification and cooling. Specimens showed variation in mechanical properties, namely Young’s modulus (65–78 GPa), yield stress (80–150 MPa), ultimate tensile strength (115–225 MPa) and elongation at break (0.75–1.4%). Furthermore, the failure localisation and character were altered with the change in gauge cross-section orientation. DIC analysis allowed correct strain evaluation that overcame the load frame compliance effect and helped to identify the unevenness of deformation distribution (plasticity waves), which ultimately resulted in exceptionally high strain localisation near the ultimate failure crack position.

In-situ monitoring for liquid metal jetting using a millimeter-wave impedance diagnostic

This article presents a millimeter-wave diagnostic for the in-situ monitoring of liquid metal jetting additive manufacturing systems. The diagnostic leverages a T-junction waveguide device to monitor impedance changes due to jetted metal droplets in real time. An analytical formulation for the time-domain T-junction operation is presented and supported with a quasi-static full-wave electromagnetic simulation model. The approach is evaluated experimentally with metallic spheres of known diameters ranging from 0.79 to 3.18 mm. It is then demonstrated in a custom drop-on-demand liquid metal jetting system where effective droplet diameters ranging from 0.8 to 1.6 mm are detected. Experimental results demonstrate that this approach can provide information about droplet size, timing, and motion by monitoring a single parameter, the reflection coefficient amplitude at the input port. These results show the promise of the impedance diagnostic as a reliable in-situ characterization method for metal droplets in an advanced manufacturing system.

316L Stainless Steel Powders for Additive Manufacturing: Relationships of Powder Rheology, Size, Size Distribution to Part Properties

Laser-Powder Bed Fusion (L-PBF) of metallic parts is a highly multivariate process. An understanding of powder feedstock properties is critical to ensure part quality. In this paper, a detailed examination of two commercial stainless steel 316L powders produced using the gas atomization process is presented. In particular, the effects of the powder properties (particle size and shape) on the powder rheology were examined. The results presented suggest that the powder properties strongly influence the powder rheology and are important factors in the selection of suitable powder for use in an additive manufacturing (AM) process. Both of the powders exhibited a strong correlation between the particle size and shape parameters and the powder rheology. Optical microscope images of melt pools of parts printed using the powders in an L-PBF machine are presented, which demonstrated further the significance of the powder morphology parameters on resulting part microstructures.

Additive manufacturing of biodegradable porous orthopaedic screw

Advent of additive manufacturing in biomedical field has nurtured fabrication of complex, customizable and reproducible orthopaedic implants. Layer-by-layer deposition of biodegradable polymer employed in development of porous orthopaedic screws promises gradual dissolution and complete metabolic resorption thereby overcoming the limitations of conventional metallic screws. In the present study, screws with different pore sizes (916 × 918 μm to 254 × 146 μm) were 3D printed at 200 μm layer height by varying printing parameters such as print speed, fill density and travel speed to augment the bone ingrowth. Micro-CT analysis and scanning electron micrographs of screws with 45% fill density confirmed porous interconnections (40.1%) and optimal pore size (259 × 207 × 200 μm) without compromising the mechanical strength (24.58 ± 1.36 MPa). Due to the open pore structure, the 3D printed screws showed increased weight gain due to the deposition of calcium when incubated in simulated body fluid. Osteoblast-like cells attached on screw and infiltrated into the pores over 14 days of in vitro culture. Further, the screws also supported greater human mesenchymal stem cell adhesion, proliferation and mineralized matrix synthesis over a period of 21 days in vitro culture as compared to non-porous screws. These porous screws showed significantly increased vascularization in a rat subcutaneous implantation as compared to control screws. Porous screws produced by additive manufacturing may promote better osteointegration due to enhanced mineralization and vascularization.

Multi-Scale Surface Treatments of Titanium Implants for Rapid Osseointegration: A Review

The propose of this review was to summarize the advances in multi-scale surface technology of titanium implants to accelerate the osseointegration process. The several multi-scaled methods used for improving wettability, roughness, and bioactivity of implant surfaces are reviewed. In addition, macro-scale methods (e.g., 3D printing (3DP) and laser surface texturing (LST)), micro-scale (e.g., grit-blasting, acid-etching, and Sand-blasted, Large-grit, and Acid-etching (SLA)) and nano-scale methods (e.g., plasma-spraying and anodization) are also discussed, and these surfaces are known to have favorable properties in clinical applications. Functionalized coatings with organic and non-organic loadings suggest good prospects for the future of modern biotechnology. Nevertheless, because of high cost and low clinical validation, these partial coatings have not been commercially available so far. A large number of in vitro and in vivo investigations are necessary in order to obtain in-depth exploration about the efficiency of functional implant surfaces. The prospective titanium implants should possess the optimum chemistry, bionic characteristics, and standardized modern topographies to achieve rapid osseointegration.

Process-Induced Fiber Orientation in Fused Filament Fabrication

As the applications for additive manufacturing have continued to grow, so too has the range of available materials, with more functional or better performing materials constantly under development. This work characterizes a copper-filled polyamide 6 (PA6) thermoplastic composite designed to enhance the thermal conductivity of fused filament fabrication (FFF) parts, especially for heat transfer applications. The composite was mixed and extruded into filament using twin screw extrusion. Because the fiber orientation within the material governs the thermal conductivity of the material, the orientation was measured in the filament, through the nozzle, and in printed parts using micro-computed tomography. The thermal conductivity of the material was measured and achieved 4.95, 2.38, and 0.75 W/(m·K) at 70 °C in the inflow, crossflow, and thickness directions, respectively. The implications of this anisotropy are discussed using the example of an air-to-water crossflow heat exchanger. The lower conductivity in the crossflow direction reduces thermal performance due to the orientation in thin-walled parts.