Masters thesis of engineering topological design of porous titanium alloy scaffolds for additive manufacturing of orthopaedic implant applications

Topological design of porous titanium alloy scaffolds for additive manufacturing of orthopaedic implant applications A thesis submitted in fulfilment of the requirements for the degree of Master of Engineering Li Yuan Bachelor of Engineering, RMIT University School of Engineering College of Science, Technology, Engineering and Maths RMIT University August 2020 Declaration I certify that except where due acknowledgement has been made, the work is that of the author alone; the work has not been submitted previously, in whole or in part, to qualify for any other academic award; the content of the thesis is the result of work which has been carried out since the official commencement date of the approved research program; any editorial work, paid or unpaid, carried out by a third party is acknowledged; and, ethics procedures and guidelines have been followed I acknowledge the support I have received for my research through the provision of an Australian Government Research Training Program Scholarship Li Yuan 4th August, 2020 Acknowledgements I would first like to thank my supervisors, Professor Songlin Ding and Distinguished Professor Cuie Wen for their support, assistance, supervision, and guidance throughout my thesis Without their help, this would not have been possible Additionally, I would like to thank Dr Guangxian Li for his kind assistance in the analysis and interpretation of data relating to the project During the two years, I have learnt a lot under their guidance, and their expertise and advice have been enormously valuable throughout my research program My particularly thanks go to my parents and my wife for their understanding and support Table of Contents Declaration Acknowledgements List of Figures Nomenclature 10 Abstract 13 Chapter Introduction 15 1.1 Background 15 1.2 Research Scopes 18 1.3 Research questions 18 1.4 Research objectives, innovations and contributions 19 1.5 Thesis outline 21 1.6 Summary 23 Chapter Literature Review 24 2.1 Bio-related properties 24 2.1.1 Non-toxicity and biocompatibility 25 2.1.2 Biomechanical properties 26 2.1.3 Biodegradability for temporary implant materials 27 2.2 Porous structure and porosity of implant materials 29 2.2.1 Porous structure with appropriate pore size and porosity 30 2.2.2 Effect of porosity on biocompatibility 30 2.2.3 Effect of porosity on mechanical properties 33 2.2.4 Effect of porosity on biodegradability 35 2.3 An overview of additive manufacturing (AM) 36 2.3.1 AM procedures 40 2.3.2 Metallic AM techniques 41 2.3.3 Other AM techniques 43 2.3.4 SLS and SLM 44 2.3.5 EBM 51 2.3.6 Metallic biomaterials fabricated by AM for implant applications 55 2.4 Summary 57 Chapter Structure design and modelling 58 Triply periodic minimal surface (TPMS) structures 58 3.2 Gyroid structure 3D modelling and procedures 67 3.3 Summary 73 Chapter Structure analysis 74 4.1 Models preparation for finite element analysis and basic theories 74 4.2 Young’s modulus analysis 79 4.3 Further analysis of gyroid scaffold and introduced cubic 85 4.4 Summary 89 Chapter Conclusions 90 References 93 Appendices .108 List of Figures Figure 1.1 Orthopedic implants in a knee replacement surgery 16 Figure 1.2 The structure of the thesis 23 Figure 2.1 Magnesium scaffold structure for biomedical application 26 Figure 2.2 Cross-section of human femur with porous structure (trabecular & cortical bone) 29 Figure 2.3 Ti scaffolds with 70% porosity and different ranges of pore sizes [41] 32 Figure 2.4 Scheme of a SLM machine [84] 45 Figure 2.5 SEM images of Ti6Al4V gyroid lattice surfaces fabricated by SLM: (a) and (b) asbuilt, (c) and (d) after post treatments (heat treatment and sandblasting) [88] 48 Figure 2.6 CP-Ti scaffolds fabricated by different AM methods (a) SLM (b) EBM 50 Figure 2.7 SEM images of Tie6Ale4V gyroid lattices surfaces fabricated by EBM: (a) as-built, (b) after post treatment of ceramic blasting [20] 52 Figure 2.8 (a) Schematic of an EBM machine and (b) its processing chamber [91,92] 54 Figure 3.1 Primitive TPMS unit cell and Primitive TPMS structure 59 Figure 3.2 Gyroid unit cell with ± 0.6 offset 60 Figure 3.3 3D CAD gyroid unit cells: (a) mm sheet solid gyroid unit cell with 0.3 mm offset thickness and (b) mm network solid gyroid unit cell at 50% volume fraction 65 Figure 3.4 A block of a 3D CAD gyroid scaffold in different views (constituted by mm network solid gyroid unit cell) 66 Figure 3.5 (a) a single unit gyroid surface covered by a cubic block (b) a single cell of network based gyroid 69 Figure 3.6 Gyroid surfaces and network-based on gyroid unit cell with different offset (α) values: (a) a mm network-based gyroid structure in an × × mm cubic; (b-1) gyroid surface without offset, (b-2) network-based gyroid unit cell without offset, (c-1) g 71 Figure 3.7 Schematic of a normal pore and a deformed pore 73 Figure 4.1 The scaffold structure in stl format ind different views (a) top view (b) front view (c) 3-dimensional view (d) righ-side view 77 Figure 4.2 Cross-section of gyroid scaffold in stl format 78 Figure 4.3 Cross-section of single unit gyroid (fulfilled) 79 Figure 4.4 (a) 3mm gyroid unit cell under compression (b) 3mm gyroid unit cell under under tension (c) the Ti scaffold structure under compression (d) the Ti scaffold structure under tension 81 Figure 4.5 mm gyroid unit cell compression 83 Figure 4.6 1×2×3 units compression 84 Figure 4.7 mm gyroid unit cell tension 84 Figure 4.8 2×2×3 units compression 85 Figure 4.9 mm unit cubic cell modelling and simulation (b) 1×2×3 units cubic scaffold modelling and (c) meshing (d) simulative results of cubic unit cell (e) simulative results of cubic unit scaffold 87 Figure 4.10 Computational result of 3mm gyroid scaffold under compression 88 Figure 4.11 Computational result of 3mm cubic scaffold under compression 89 List of Tables Table Summary of different AM methods…………………………………………38 Table Features of SLM and EBM in comparison……… ……………………………49 Table Summary of different as-built 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Density of the bulk alloy; ρmaterial Density of the porous structure; σpl Plastic collapse strength; E Elastic modulus of the porous material; ρ Density of the porous material; ρs Density of the... important for implant design 2.1.3 Biodegradability for temporary implant materials Recently, the fabrication of metal implants with an open-cellular structure using advanced additive manufacturing. .. behaviour of different scaffolds is going to be investigated, which will be the principle for the optimization of the structure design of scaffolds The fabrication process of the scaffolds will be