Three-dimensional printed titanium chest wall reconstruction for tumor removal in the sternal region.

Resection of thoracic wall tumors results in significant defects in the chest wall, leading to various complications. In recent years, the use of three-dimensional (3D) printed titanium alloy prostheses in clinical practice has demonstrated enhanced outcomes in chest wall reconstruction surgery. A cohort of seven patients with sternal tumors was identified for this study. Following a helical CT scan, a digital model was generated for the design of the prosthesis. Subsequently, the tumors were then removed together with the affected sternum and ribs. The chest wall was then reconstructed using 3D-printed titanium alloy prosthesis for bone reconstruction, mesh for pleural reconstruction, and flap for soft tissue reconstruction. Patients were monitored for a period of one year post-surgery. In the seven cases examined, the tumors were found in various locations with varying degrees of invasion. Based on the scope of surgical resection and the size of the defect, 3D-printed titanium alloy prosthesis was custom-designed for chest wall reconstruction. Prior to bone reconstruction, pleural reconstruction was achieved with Bard Composix E/X Mesh, while soft tissue repair involved muscle flap and musculocutaneous flap procedures. A one-year follow-up assessment revealed that the utilization of the 3D-printed titanium alloy prosthesis led to secure fixation, favorable histocompatibility, and enhanced lung function. The findings demonstrate that the utilization of 3D printed titanium alloy prostheses represents a significant advancement in the field of chest wall reconstruction and thoracic surgical procedures.

Enhanced osseointegration and antimicrobial properties of 3D-Printed porous titanium alloys with copper-strontium doped calcium silicate coatings.

The 3D printing of porous titanium scaffolds reduces the elastic modulus of titanium alloys and promotes osteogenic integration. However, due to the biological inertness of titanium alloy materials, the implant-bone tissue interface is weakly bonded. A calcium silicate (CS) coating doped with polymetallic ions can impart various biological properties to titanium alloy materials. In this study, CuO and SrO binary-doped CS coatings were prepared on the surface of 3D-printed porous titanium alloy scaffolds using atmospheric plasma spraying and characterized by SEM, EDS, and XRD. Both CuO and SrO were successfully incorporated into the CS coating. The in vivo osseointegration evaluation of the composite coating-modified 3D-printed porous titanium alloy scaffolds was conducted using a rabbit bone defect model, showing that the in vivo osseointegration of 2% CuO-10% SrO-CS-modified 3D-printed porous titanium alloy was improved. The in vitro antimicrobial properties of the 2% CuO-10% SrO-CS-modified 3D-printed porous titanium alloy were evaluated through bacterial platform coating, co-culture liquid absorbance detection, and crystal violet staining experiments, demonstrating that the composite coating exhibited good antimicrobial properties. In conclusion, the composite scaffold possesses both osteointegration-promoting and antimicrobial properties, indicating a broad potential for clinical applications.

Small Punch Testing of a Ti6Al4V Titanium Alloy and Simulations under Different Stress Triaxialities.

The mechanical properties of local materials subjected to various stress triaxialities were investigated via self-designed small punch tests and corresponding simulations, which were tailored to the geometry and notch forms of the samples. The finite element model was developed on the basis of the actual test method. After verifying the accuracy of the simulation, the stress, strain, and void volume fraction distributions of the Ti6Al4V titanium alloy under different stress states were compared and analyzed. The results indicate that the mechanical properties of the local material significantly differ during downward pressing depending on the geometric shape. A three-dimensional tensile stress state was observed in the center area, where the void volume fraction was greater than the fracture void volume fraction. The fracture morphology of the samples further confirmed the presence of different stress states. Specifically, the fracture morphology of the globular head samples (with or without U-shaped notches) predominantly featured dimples. Modifying the specimen's geometry effectively increased stress triaxiality, facilitating the determination of the material's constitutive relationship under varying stress states.

Influence of Laser Power and Rotational Speed on the Surface Characteristics of Rotational Line Spot Nanosecond Laser Ablation of TC4 Titanium Alloy.

The TC4 titanium alloy is widely used in medical, aerospace, automotive, shipbuilding, and other fields due to its excellent comprehensive properties. As an advanced processing technology, laser processing can be used to improve the surface quality of TC4 titanium alloy. In the present research, a new type of rotational laser processing method was adopted, by using a beam shaper to modulate the Gaussian spot into a line spot, with uniform energy distribution. The effects of the laser power and rotational speed on the laser ablation surface of the TC4 titanium alloy were analyzed. The results reveal that the melting mechanism of the material surface gradually changes from surface over melt to surface shallow melt with the increase in the measurement radius and the surface roughness increases first, then decreases and, finally, tends to be stable. By changing the laser power, the surface roughness changes significantly with the variation in the measurement radius. Because low laser power cannot provide sufficient laser energy, the measurement radius corresponding to the surface roughness peak of the microcrack area is reduced. Under a laser power of 11 W, the surface roughness reaches its peak when the measurement radius is 600 µm, which is 200 µm lower than that of a laser power of 12 W, 13 W, and 14 W. By changing the rotational speed, the centrifugal force generated by the rotation of the specimen affects the distribution and re-condensation of the molten pool of the surface. As the rotational speed increases, the shallow pit around the pit is made shallower by the filling of the pit with molten material and the height of the bulge decreases, until it disappears. The surface oxygen content of the material increases first and then decreases with the increase in the measurement radius and gradually approaches the initial surface state. Compared with a traditional laser processing spot, the rotational line spot covers a larger processing area of 22.05 mm2. This work can be used as the research basis for rotational modulation laser polishing and has significance for guiding the innovative development of high-quality and high-efficiency laser processing technology.

Simulation Study on Residual Stress Distribution of Machined Surface Layer in Two-Step Cutting of Titanium Alloy.

Ti-6Al-4V titanium alloy is known as one of the most difficult metallic materials to machine, and the machined surface residual stress distribution significantly affects properties such as static strength, fatigue strength, corrosion resistance, etc. This study utilized finite element software Abaqus 2020 to simulate the two-step cutting process of titanium alloy, incorporating stages of cooling, unloading, and de-constraining of the workpiece. The chip morphology and cutting force obtained from orthogonal cutting tests were used to validate the finite element model. Results from the orthogonal cutting simulations revealed that with increasing cutting speed and the tool rake angle, the residual stress undergoes a transition from compressive to tensile stress. To achieve greater residual compressive stress during machining, it is advisable to opt for a negative rake angle coupled with a lower cutting speed. Additionally, in two-step machining of titanium alloy, the initial cutting step exerts a profound influence on the subsequent cutting step, thereby shortening the evolution time of the Mises stress, equivalent plastic strain, and stiffness damage equivalent in the subsequent cutting step. These results contribute to optimizing titanium alloy machining processes by providing insights into controlling residual stress, ultimately enhancing product quality and performance of structural part of titanium alloy.

Study on Laser Transmission Welding Technology of TC4 Titanium Alloy and High-Borosilicate Glass.

As the demand for high-performance dissimilar material joining continues to increase in fields such as aerospace, biomedical engineering, and electronics, the welding technology of dissimilar materials has become a focus of research. However, due to the differences in material properties, particularly in the welding between metals and non-metals, numerous challenges arise. The formation and quality of the weld seam are strongly influenced by laser process parameters. In this study, successful welding of high-borosilicate glass to a TC4 titanium alloy, which was treated with high-temperature oxidation, was achieved using a millisecond pulsed laser. A series of process parameter comparison experiments were designed, and the laser welding behavior of the titanium alloy and glass under different process parameters was investigated using scanning electron microscopy (SEM) and a universal testing machine as the primary analysis and testing equipment. The results revealed that changes in process parameters significantly affect the energy input and accumulation during the welding process. The maximum joint strength of 60.67 N was obtained at a laser power of 180 W, a welding speed of 3 mm/s, a defocus distance of 0 mm, and a frequency of 10 Hz. Under the action of the laser, the two materials mixed and penetrated into the molten pool, thus achieving a connection. A phase, Ti5Si3, was detected at the fracture site, indicating that both mechanical bonding and chemical bonding reactions occurred between the high-borosilicate glass and the TC4 titanium alloy during the laser welding process.

Texture of Hot-Compressed Metastable ß-Titanium Alloy Ti5321 Studied by Neutron Diffraction.

The textures of the ß- and α-phases of the metastable ß-titanium alloy Ti5321 after hot deformation were investigated by neutron diffraction. A hot-rolled bar was solutionized in the ß-phase field and then hot compressed above and below the ß-transus temperature. The initial texture after full recrystallization and grain growth in the ß-phase field exhibits a weak cube component {001}<100> and minor {112}<110> and {111}<110> components. After hot compression, a <100> fiber texture is observed, increasing in intensity with compression temperature. Below the ß-transus temperature, dynamic recrystallization of the ß-phase and dynamic spheroidization of the α-phase interact strongly. The texture of the α-phase is a <11-20> fiber texture, increasing in intensity with decreasing compression temperature. The mechanisms of texture formation during hot compression are discussed.

A Liquid Metal-Based Temperature-Responsive Low-Toxic Smart Coating for Anti-Biofouling Applications in Marine Engineering.

Titanium alloys have been widely used in marine engineering fields. However, because of high biocompatibility, they are vulnerable to biofouling. In this work, based on the micro-arc oxidation technology and spontaneous galvanic replacement reaction, a temperature-responsive low-toxic smart coating consisting of liquid metal particles is designed to control the release of Ga3+, Cu2+, and Cu1+ ions in different temperatures. This technology can ensure the full release of active ingredients within the target temperature range, intelligently maintaining the excellent anti-biofouling performance, while saving active ingredients. After being immersed in culture media with Sulfate-Reducing Bacteria (SRB) for 14 days at 10, 20, and 30 °C, at the optimal activity temperature of 30 °C for SRB, the best sample releases the highest amounts of Ga3+, Cu2+, and Cu1+ ions, demonstrating a 99.9% bactericidal rate. When the temperature decreases to 10 °C, the activity level of SRB is very low, and the smart coating can also reduce the released ions correspondingly, still with a 97.3% bactericidal rate. The remarkable anti-biofouling performance is attributed to the physical damage and lethal ions interaction. Furthermore, the best sample exhibits good corrosion resistance. This work presents a design route for smart anti-biofouling coatings for temperature-responsive.

Comparison In Vitro Study on the Interface between Skin and Bone Cell Cultures and Microporous Titanium Samples Manufactured with 3D Printing Technology Versus Sintered Samples.

Percutaneous implants osseointegrated into the residuum of a person with limb amputation need to provide mechanical stability and protection against infections. Although significant progress has been made in the biointegration of percutaneous implants, the problem of forming a reliable natural barrier at the level of the surface of the implant and the skin and bone tissues remains unresolved. The use of a microporous implant structure incorporated into the Skin and Bone Integrated Pylon (SBIP) should address the issue by allowing soft and bone tissues to grow directly into the implant structure itself, which, in turn, should form a reliable barrier to infections and support strong osseointegration. To evaluate biological interactions between dermal fibroblasts and MC3T3-E1 osteoblasts in vitro, small titanium discs (with varying pore sizes and volume fractions to achieve deep porosity) were fabricated via 3D printing and sintering. The cell viability MTT assay demonstrated low cytotoxicity for cells co-cultured in the pores of the 3D-printed and sintered Ti samples during the 14-day follow-up period. A subsequent Quantitative Real-Time Polymerase Chain Reaction (RT-PCR) analysis of the relative gene expression of biomarkers that are associated with cell adhesion (α2, α5, αV, and ß1 integrins) and extracellular matrix components (fibronectin, vitronectin, type I collagen) demonstrated that micropore sizes ranging from 200 to 500 µm of the 3D printed and sintered Ti discs were favorable for dermal fibroblast adhesion. For example, for representative 3D-printed Ti sample S6 at 72 h the values were 4.71 ± 0.08 (α2 integrin), 4.96 ± 0.08 (α5 integrin), 4.71 ± 0.08 (αV integrin), and 1.87 ± 0.12 (ß1 integrin). In contrast, Ti discs with pore sizes ranging from 400 to 800 µm demonstrated the best results (in terms of marker expression related to osteogenic differentiation, including osteopontin, osteonectin, osteocalcin, TGF-ß1, and SMAD4) for MC3T3-E1 cells. For example, for the representative 3D sample S4 on day 14, the marker levels were 11.19 ± 0.77 (osteopontin), 7.15 ± 0.29 (osteonectin), and 6.08 ± 0.12 (osteocalcin), while for sintered samples the levels of markers constituted 5.85 ± 0.4 (osteopontin), 4.45 ± 0.36 (osteonectin), and 4.46 ± 0.3 (osteocalcin). In conclusion, the data obtained show the high biointegrative properties of porous titanium structures, while the ability to implement several pore options in one structure using 3D printing makes it possible to create personalized implants for the best one-time integration with both skin and bone tissues.

3D-printed titanium scaffolds loaded with gelatin hydrogel containing strontium-doped silver nanoparticles promote osteoblast differentiation and antibacterial activity for bone tissue engineering.

Bone tissue engineering offers a promising alternative to stimulate the regeneration of damaged tissue, overcoming the limitations of conventional autografts and allografts. Recently, titanium alloy (Ti) implants have garnered significant attention for treating critical-sized bone defects, especially with the advancement of 3D printing technology. Although Ti alloys have impressive versatility, their lack of cellular adhesion, osteogenic and antibacterial properties are significant factors that contribute to their failure. Hence, to overcome these obstacles, this study aimed to incorporate osteoinductive and antibacterial cue-loaded hydrogels into 3D-printed Ti (3D-Ti) scaffolds. 3D-Ti scaffolds were synthesized using the direct metal laser sintering method and loaded with a gelatin (Gel) hydrogel containing strontium-doped silver nanoparticles (Sr-Ag NPs). Compared with Ag NPs, Sr-doped Ag NPs increased the expression of Runx2 mRNA, which is a key bone transcription factor. We subjected the bioactive 3D-hybrid scaffolds (3D-Ti/Gel/Sr-Ag NPs) to physicochemical and material characterization, followed by cytocompatibility and osteogenic evaluation. The microporous and macroporous topographies of the scaffolds with Sr-Ag NPs showed increased Runx2 expression and matrix mineralization, with potent antibacterial properties. Therefore, the 3D-Ti scaffolds incorporated with Sr-Ag NP-loaded Gel hydrogels favored osteoblast differentiation and antibacterial activity, indicating their potential for orthopedic applications.