Effect of Layer Thickness and Heat Treatment on Microstructure and Mechanical Properties of Alloy 625 Manufactured by Electron Beam Powder Bed Fusion.

This research program investigated the effects of layer thickness (50 µm and 100 µm) on the microstructure and mechanical properties of electron beam powder bed fusion (EBPBF) additive manufacturing of Inconel 625 alloy. The as-built 50 µm and 100 µm layer thickness components were also heat treated at temperatures above 1100 °C which produced a recrystallized grain structure containing annealing twins in the 50 µm layer thickness components, and a duplex grain structure consisting of islands of very small equiaxed grains dispersed in a recrystallized, large-grain structure containing annealing twins. The heat-treated components of the microstructures and mechanical properties were compared with the as-built components in both the build direction (vertical) and perpendicular (horizontal) to the build direction. Vickers microindentation hardness (HV) values for the vertical and horizontal geometries averaged 227 and 220 for the as-built 50 µm and 100 µm layer components, respectively, and 185 and 282 for the corresponding heat-treated components. The yield stress values were 387 MPa and 365 MPa for the as-built horizontal and vertical 50 µm layer geometries, and 330 MPa and 340 MPa for the as-built 100 µm layer components. For the heat-treated 50 µm components, the yield stress values were 340 and 321 MPa for the horizontal and vertical geometries, and 581 and 489 MPa for the 100 µm layer components, respectively. The elongation for the 100 µm layer as-built horizontal components was 28% in contrast with 65% for the corresponding 100 µm heat-treated layer components, an increase of 132% for the duplex grain structure.

Investigation of Microstructure and Mechanical Properties for Ti-6Al-4V Alloy Parts Produced Using Non-Spherical Precursor Powder by Laser Powder Bed Fusion.

An unmodified, non-spherical, hydride-dehydride (HDH) Ti-6Al-4V powder having a substantial economic advantage over spherical, atomized Ti-6Al-4V alloy powder was used to fabricate a range of test components and aerospace-related products utilizing laser beam powder-bed fusion processing. The as-built products, utilizing optimized processing parameters, had a Rockwell-C scale (HRC) hardness of 44.6. Following heat treatments which included annealing at 704 °C, HIP at ~926 °C (average), and HIP + anneal, the HRC hardnesses were observed to be 43.9, 40.7, and 40.4, respectively. The corresponding tensile yield stress, UTS, and elongation for these heat treatments averaged 1.19 GPa, 1.22 GPa, 8.7%; 1.03 GPa, 1.08 GPa, 16.7%; 1.04 GPa, 1.09 GPa, 16.1%, respectively. The HIP yield strength and elongation of 1.03 GPa and 16.7% are comparable to the best commercial, wrought Ti-6Al-4V products. The corresponding HIP component microstructures consisted of elongated small grains (~125 microns diameter) containing fine, alpha/beta lamellae.

Development and Evaluation of an Automated Manual Resuscitator-Based Emergency Ventilator-Alternative.

Mass casualty incidents such as those that are being experienced during the novel coronavirus disease (COVID-19) pandemic can overwhelm local healthcare systems, where the number of casualties exceeds local resources and capabilities in a short period of time. The influx of patients with lung function deterioration as a result of COVID-19 has strained traditional ventilator supplies. To bridge the gap during ventilator shortages and to help clinicians triage patients, manual resuscitator devices can be used to deliver respirations to a patient requiring breathing support. Bag-valve mask (BVM) devices are ubiquitous in ambulances and healthcare environments, however require a medical professional to be present and constantly applying compression to provide the patient with respirations. We developed an automated manual resuscitator-based emergency ventilator-alternative (AMREV) that provides automated compressions of a BVM in a repetitive manner and is broadly compatible with commercially-available BVM devices approximately 5 inches (128 mm) in diameter. The AMREV device relieves the medical professional from providing manual breathing support and allows for hands-free operation of the BVM. The AMREV supports the following treatment parameters: 1) adjustable tidal volume (V T ), 2) positive end-expiratory pressure (PEEP) (intrinsic and/or external), 3) 1:1 inspiratory: expiratory ratio, and 4) a controllable respiratory rate between 10-30 breaths per minute. The relationship between the inherent resistance and compliance of the lung and the delivered breaths was assessed for the AMREV device. Adjustable V T of 110-700 ml was achieved within the range of simulated lung states. A linear increase in mean airway pressure (P aw ), from 10-40 cmH2O was observed, as the resistance and compliance on the lung model moved from normal to severe simulated disease states. The AMREV functioned continuously for seven days with less than 3.2% variation in delivered V T and P aw . Additionally, the AMREV device was compatible with seven commercially-available BVM setups and delivered consistent V T and P aw within 10% between models. This automated BVM-based emergency-use resuscitator can provide consistent positive pressure, volume-controlled ventilation over an extended duration when a traditional ventilator is not available. True ventilator shortages may lead to manual resuscitators devices such as the AMREV being the only option for some healthcare systems during the COVID-19 pandemic.

Effects of Postprocess Hot Isostatic Pressing Treatments on the Mechanical Performance of EBM Fabricated TI-6Al-2Sn-4Zr-2Mo.

An essentially fully acicular alpha-prime martensite within an equiaxed grain structure was produced in an Electron Beam Melting (EBM)-fabricated Ti-6Al-2Sn-4Zr-2Mo (Ti6242) alloy using two different Arcam EBM machines: An A2X system employing tungsten filament thermionic electron emission, and a Q20 system employing LaB6 thermionic electron emission. Post-process Hot Isostatic Pressing (HIP) treatment for 2 h at 850, 950, and 1050 °C resulted in grain refinement and equiaxed grain growth along with alpha-prime martensite decomposition to form an intragranular mixture of acicular martensite and alpha at 850 °C, and acicular alpha phase at 950 and 150 °C, often exhibiting a Widmanstätten (basketweave) structure. The corresponding tensile yield stress and ultimate tensile strength (UTS) associated with the grain growth and acicular alpha evolution decreased from ~1 and ~1.1 GPa, respectively, for the as-fabricated Ti6242 alloy to ~0.8 and 0.9 GPa, respectively, for HIP at 1050 °C. The optimum elongation of ~15-16% occurred for HIP at 850 °C; for both EBM systems. Because of the interactive role played by equiaxed grain growth and the intragrain, acicular alpha microstructures, the hardness varied only by ~7% between 41 and 38 HRC.

Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts with Embedded Wires for High Current-Carrying Applications.

Fabrication of parts exhibiting multi-functionality has recently been complemented by hybrid polymer extrusion additive manufacturing in combination with wire embedding technology. While much mechanical characterization has been performed on parts produced with fused deposition modeling, limited characterization has been performed when combined electrical and thermal loads are applied to 3D printed multi-material parts. As such, this work describes the design, fabrication, and testing of 3D printed thermoplastic coupons containing embedded copper wires that carried current. An automated fabrication process was used employing a hybrid additive manufacturing machine that dispensed polycarbonate thermoplastic and embedded bare copper wires. Testing included AC and DC hipot testing as well as thermal testing on as-fabricated and heat treated coupons to determine the effect of porosity in the substrate. The heat-treated parts contained reduced amounts of porosity, as corroborated through scanning electron microscopy, which led to 50 % increased breakdown strength and 30 to 40 % increased heat dissipation capabilities. The results of this research are describing a set of design protocol that can be used as a guideline for 3D printed embedded electronics to predict the electrical and thermal behavior.

Effect of headless compression screw on construct stability for centre of rotation and angulation-based levelling osteotomy. Biomechanical testing in flexion and torsion.

OBJECTIVE: To compare the biomechanical properties of bone and implant constructs when used for the centre of rotation and angulation (CORA) based levelling osteotomy, with and without implantation of a trans-osteotomy headless compression screw tested under three-point flexural and torsional forces; thereby determining the contribution of a trans-osteotomy headless compression screw with regards to stability of the construct. METHODS: Experimental biomechanical study utilizing 12 pairs of cadaveric canine tibias. Using the CORA based levelling osteotomy (CBLO) procedure, the osteotomy was stabilized with either a standard non-locking CBLO bone plate augmented with a headless compression screw (HCS) or a CBLO bone plate alone. Tibial constructs were mechanically tested in three-point craniocaudal flexural testing or in torsion. RESULTS: In three-point flexural testing, the difference between the two constructs was not significant. In torsion, the difference in the angle of failure between constructs with a HCS (48.46°) and constructs without a HCS (81.65°) was significant (p = 0.036). Maximum torque achieved by constructs with a HCS (21.7 Nm) was greater than those without (18.7 Nm) (p = 0.056). Stiffness differences between both groups in torsion and bending were not significant. Use of a HCS did increase the stability of the CBLO construct in torsional testing, but not in flexural testing.

Microstereolithography and characterization of poly(propylene fumarate)-based drug-loaded microneedle arrays.

Drug-loaded microneedle arrays for transdermal delivery of a chemotherapeutic drug were fabricated using multi-material microstereolithography (µSL). These arrays consisted of twenty-five poly(propylene fumarate) (PPF) microneedles, which were precisely orientated on the same polymeric substrate. To control the viscosity and improve the mechanical properties of the PPF, diethyl fumarate (DEF) was mixed with the polymer. Dacarbazine, which is widely used for skin cancer, was uniformly blended into the PPF/DEF solution prior to crosslinking. Each microneedle has a cylindrical base with a height of 700 µm and a conical tip with a height of 300 µm. Compression test results and characterization of the elastic moduli of the PPF/DEF (50:50) and PPF/drug mixtures indicated that the failure force was much larger than the theoretical skin insertion force. The release kinetics showed that dacarbazine can be released at a controlled rate for five weeks. The results demonstrated that the PPF-based drug-loaded microneedles are a potential method to treat skin carcinomas. In addition, µSL is an attractive manufacturing technique for biomedical applications, especially for micron-scale manufacturing.

Single-lumen and multi-lumen poly(ethylene glycol) nerve conduits fabricated by stereolithography for peripheral nerve regeneration in vivo.

BACKGROUND: The use of nerve conduits to facilitate nerve regrowth after peripheral nerve injury is limited to defects less than 3 cm. The purpose of this study is to determine the capability of novel single and multi-lumen poly(ethylene glycol) (PEG) conduits manufactured by stereolithography to promote peripheral nerve regeneration. MATERIALS AND METHODS: Eight Sprague Dawley rats with sharp transection injuries of the sciatic nerve were randomly assigned to receive single-lumen or multi-lumen PEG conduits to bridge a 10-mm gap. Sciatic nerve and conduit samples were harvested after 5 weeks, and axon number, myelin thickness, fiber diameter, and g-ratio were analyzed. The contralateral intact nerve was also harvested for comparison. RESULTS: Partial nerve regeneration was observed in three out of four single-lumen conduits and one out of four multi-lumen conduits. Axon number in the single-lumen regenerated nerve approached that of the contralateral intact nerve at 4,492 ± 2,810.0 and 6,080 ± 627.9 fibers/mm(2), respectively. The percentage of small fibers was greater in the single-lumen conduit compared with the intact nerve, whereas myelin thickness and g-ratio were consistently greater in the autologous nerve. Axon regrowth through the multi-lumen conduits was severely limited. CONCLUSION: Single-lumen stereolithography-manufactured PEG nerve conduits promote nerve regeneration, with regenerating axon numbers approaching that of normal nerve. Multi-lumen conduits demonstrated significantly less nerve regeneration, possibly due to physical properties of the conduit inhibiting growth. Further studies are necessary to compare the efficacy of the two conduits for functional recovery and to elucidate the reasons underlying their differences in nerve regeneration potential.

Next generation orthopaedic implants by additive manufacturing using electron beam melting.

This paper presents some examples of knee and hip implant components containing porous structures and fabricated in monolithic forms utilizing electron beam melting (EBM). In addition, utilizing stiffness or relative stiffness versus relative density design plots for open-cellular structures (mesh and foam components) of Ti-6Al-4V and Co-29Cr-6Mo alloy fabricated by EBM, it is demonstrated that stiffness-compatible implants can be fabricated for optimal stress shielding for bone regimes as well as bone cell ingrowth. Implications for the fabrication of patient-specific, monolithic, multifunctional orthopaedic implants using EBM are described along with microstructures and mechanical properties characteristic of both Ti-6Al-4V and Co-29Cr-6Mo alloy prototypes, including both solid and open-cellular prototypes manufactured by additive manufacturing (AM) using EBM.

In vitro validation of finite element analysis of blood flow in deformable models.

The purpose of this article is to validate numerical simulations of flow and pressure incorporating deformable walls using in vitro flow phantoms under physiological flow and pressure conditions. We constructed two deformable flow phantoms mimicking a normal and a restricted thoracic aorta, and used a Windkessel model at the outlet boundary. We acquired flow and pressure data in the phantom while it operated under physiological conditions. Next, in silico numerical simulations were performed, and velocities, flows, and pressures in the in silico simulations were compared to those measured in the in vitro phantoms. The experimental measurements and simulated results of pressure and flow waveform shapes and magnitudes compared favorably at all of the different measurement locations in the two deformable phantoms. The average difference between measured and simulated flow and pressure was approximately 3.5 cc/s (13% of mean) and 1.5 mmHg (1.8% of mean), respectively. Velocity patterns also showed good qualitative agreement between experiment and simulation especially in regions with less complex flow patterns. We demonstrated the capabilities of numerical simulations incorporating deformable walls to capture both the vessel wall motion and wave propagation by accurately predicting the changes in the flow and pressure waveforms at various locations down the length of the deformable flow phantoms.

In vitro validation of finite-element model of AAA hemodynamics incorporating realistic outlet boundary conditions.

The purpose of this study is to validate numerical simulations of flow and pressure in an abdominal aortic aneurysm (AAA) using phase-contrast magnetic resonance imaging (PCMRI) and an in vitro phantom under physiological flow and pressure conditions. We constructed a two-outlet physical flow phantom based on patient imaging data of an AAA and developed a physical Windkessel model to use as outlet boundary conditions. We then acquired PCMRI data in the phantom while it operated under conditions mimicking a resting and a light exercise physiological state. Next, we performed in silico numerical simulations and compared experimentally measured velocities, flows, and pressures in the in vitro phantom to those computed in the in silico simulations. There was a high degree of agreement in all of the pressure and flow waveform shapes and magnitudes between the experimental measurements and simulated results. The average pressures and flow split difference between experiment and simulation were all within 2%. Velocity patterns showed good agreement between experimental measurements and simulated results, especially in the case of whole-cycle averaged comparisons. We demonstrated methods to perform in vitro phantom experiments with physiological flows and pressures, showing good agreement between numerically simulated and experimentally measured velocity fields and pressure waveforms in a complex patient-specific AAA geometry.

Hemodynamic comparison of differing anastomotic geometries using magnetic resonance velocimetry.

BACKGROUND: Hemodynamic factors at the distal anastomosis play an important role in prosthetic graft performance. A new magnetic resonance imaging (MRI) technique was used to determine the effect of anastomotic geometry on hemodynamic flow patterns. METHODS: Four dimensional (4D) magnetic resonance velocimetry (4D-MRV) is a noninvasive method of analyzing pulsatile flow in three dimensions (3D). End-to-side anastomotic models were constructed by suturing 6 mm polytetrafluoroethylene (ePTFE) grafts to silicone tubing (4 mm i.d.). The models included straight ePTFE, precuffed ePTFE, and patched ePTFE configurations in a pulsatile system, which created flow consistent with physiologic flow rates and pressures. Blood was simulated by a solution of 40% glycerol in distilled water with trace gadolinium. The different models were imaged using MRV techniques in a three-dimensional (3D) coronal slab (0.5 mm thick coronal slices, in-plane field of view (FOV) 18 cm.) The data were reconstructed, resulting in an interpolated resolution of 0.35 mm in each coronal plane. The 3D flow fields were represented as isosurfaces, visualizing the internal geometry of the models with streamlines tangent to the velocity vectors identifying the path of the fluid. Volumetric flow rates for each time phase were calculated by integrating the flow through cross sections of each anastomotic model. Analysis of the flow patterns focused on the anastomotic regions prone to the development of intimal hyperplasia and graft failure as identified in the literature; the toe, floor, heel, and hood. RESULTS: Conventional end-to-side geometry resulted in uniform flow with a low angle of impingement on the recipient vessel floor. A small vortex at the anastomotic heel created minimal recirculation. The precuffed geometry resulted in a large recirculation vortex of chaotic, low flow that increased throughout the pulsatile cycle. Regions of low flow velocity were noted in a substantial portion of the precuffed anastomotic configuration. Flow separation distal to the toe occurred in both geometries, but was more apparent in the precuffed configuration. The patch model had flow characteristics similar to the straight end-to-side geometry. CONCLUSION: Magnetic resonance velocimetry produces 3D, time varying velocity measurements with sufficient accuracy and resolution to analyze hemodynamics in anastomotic geometries. Flow structures in different graft configurations were effectively captured with marked differences noted between standard and precuffed anastomotic geometries. The findings support a conventional end-to-side anastomosis with a low incidence angle using a straight graft as producing favorable hemodynamics as compared to a cuffed configuration. The vein patch configuration closely approximates the conventional, straight anastomotic pattern. We believe the MRV technique has been sufficiently developed to warrant additional in vitro and in vivo studies providing insight into hemodynamic implications for the development of optimal prosthetic graft performance.

Microstructural and Process Characterization of Conductive Traces Printed from Ag Particulate Inks.

Conductive inks are key enablers for the use of printing techniques in the fabrication of electronic systems. Focus on the understanding of aspects controlling the electrical performance of conductive ink is paramount. A comparison was made between microparticle Ag inks and an Ag nanoparticle ink. The microstructures resulting from thermal cure processes were characterized morphologically and also in terms of their effect on the resistivity of printed traces. For microparticle inks, the variability of resistivity measurements between samples as defined by coefficient of variation (CV) was greater than 0.1 when the resistivity was 10 to 50 times that of bulk Ag. When the resistivity was lower (~1.4 times that of bulk Ag) the CV of sample sets was less than 0.1. In the case of the nanoparticle ink, resistivity was found to decrease by a factor ranging from 1.2 to 1.5 after doubling the amount of layers printed prior to curing though it was expected to remain the same. Increasing the amount of layers printed also enhanced the sintering process.

Fabrication of Off-the-Shelf Multilumen Poly(Ethylene Glycol) Nerve Guidance Conduits Using Stereolithography.

A manufacturing process for fabricating off-the-shelf multilumen poly(ethylene glycol) (PEG)-based nerve guidance conduits (NGCs) was developed that included the use of stereolithography (SL). A rapid fabrication strategy for complex 3D scaffolds incorporated postprocessing with lyophilization and sterilization to preserve the scaffold, creating an implantable product with improved suturability. SL is easily adaptable to changes in scaffold design, is compatible with various materials and cells, and can be expanded for mass manufacture. The fabricated conduits were characterized using optical and scanning electron microscopy, and measurements of swelling ratio, dimensional swelling factor, resistance to compression, and coefficient of friction were performed. Water absorption curves showed that the conduits after lyophilization and sterilization return easily and rapidly to a swollen state when placed in an aqueous solution, successfully maintaining their original overall structure as required for implantation. Postprocessed conduits at the swollen state were less slippery and therefore easier to handle than those without postprocessing. Suture pullout experiments showed that NGCs fabricated with a higher concentration of PEG were better able to resist suture pullout. NGCs having a multilumen design demonstrated a better resistance to compression than a single-lumen design with an equivalent surface area, as well as a greater force required to collapse the design. Conduits fabricated with a higher PEG concentration were shown to have compressive resistances comparable to those of commercially available NGCs. The use of SL with PEG and the manufacturing process developed here shows promise for improving the current state of the art in peripheral nerve repair strategies.

Combined micro and macro additive manufacturing of a swirling flow coaxial phacoemulsifier sleeve with internal micro-vanes.

Microstereolithography (microSL) technology can fabricate complex, three-dimensional (3D) microstructures, although microSL has difficulty producing macrostructures with micro-scale features. There are potentially many applications where 3D micro-features can benefit the overall function of the macrostructure. One such application involves a medical device called a coaxial phacoemulsifier where the tip of the phacoemulsifier is inserted into the eye through a relatively small incision and used to break the lens apart while removing the lens pieces and associated fluid from the eye through a small tube. In order to maintain the eye at a constant pressure, the phacoemulsifier also includes an irrigation solution that is injected into the eye during the procedure through a coaxial sleeve. It has been reported, however, that the impinging flow from the irrigation solution on the corneal endothelial cells in the inner eye can damage these cells during the procedure. As a result, a method for reducing the impinging flow velocities and the resulting shear stresses on the endothelial cells during this procedure was explored, including the design and development of a complex, 3D micro-vane within the sleeve. The micro-vane introduces swirl into the irrigation solution, producing a flow with rapidly dissipating flow velocities. Fabrication of the sleeve and fitting could not be accomplished using microSL alone, and thus, a two-part design was accomplished where a sleeve with the micro-vane was fabricated with microSL and a threaded fitting used to attach the sleeve to the phacoemulsifier was fabricated using an Objet Eden 333 rapid prototyping machine. The new combined device was tested within a water container using particle image velocimetry, and the results showed successful swirling flow with an ejection of the irrigation fluid through the micro-vane in three different radial directions corresponding to the three micro-vanes. As expected, the sleeve produced a swirling flow with rapidly dissipating streamwise flow velocities where the maximum measured streamwise flow velocities using the micro-vane were lower than those without the micro-vane by 2 mm from the tip where they remained at approximately 70% of those produced by the conventional sleeve as the flow continued to develop. It is believed that this new device will reduce damage to endothelial cells during cataract surgery and significantly improve patient outcomes from this procedure. This unique application demonstrates the utility of combining microSL with a macro rapid prototyping technology for fabricating a real macro-scale device with functional, 3D micro-scale features that would be difficult and costly to fabricate using alternative manufacturing methods.

Stereolithography of three-dimensional bioactive poly(ethylene glycol) constructs with encapsulated cells.

Stereolithography (SL) was used to fabricate complex 3-D poly(ethylene glycol) (PEG) hydrogels. Photopolymerization experiments were performed to characterize the solutions for use in SL, where the crosslinked depth (or hydrogel thickness) was measured at different laser energies and photoinitiator (PI) concentrations for two concentrations of PEG-dimethacrylate in solution (20% and 30% (w/v)). Hydrogel thickness was a strong function of PEG concentration, PI type and concentration, and energy dosage, and these results were utilized to successfully fabricate complex hydrogel structures using SL, including structures with internal channels of various orientations and multi-material structures. Additionally, human dermal fibroblasts were encapsulated in bioactive PEG photocrosslinked in SL. Cell viability was at least 87% at 2 and 24 h following fabrication. The results presented here indicate that the use of SL and photocrosslinkable biomaterials, such as photocrosslinkable PEG, appears feasible for fabricating complex bioactive scaffolds with living cells for a variety of important tissue engineering applications.