Powder Bed Fusion 3D Printing in Precision Manufacturing for Biomedical Applications: A Comprehensive Review.

Precision manufacturing requirements are the key to ensuring the quality and reliability of biomedical implants. The powder bed fusion (PBF) technique offers a promising solution, enabling the creation of complex, patient-specific implants with a high degree of precision. This technology is revolutionizing the biomedical industry, paving the way for a new era of personalized medicine. This review explores and details powder bed fusion 3D printing and its application in the biomedical field. It begins with an introduction to the powder bed fusion 3D-printing technology and its various classifications. Later, it analyzes the numerous fields in which powder bed fusion 3D printing has been successfully deployed where precision components are required, including the fabrication of personalized implants and scaffolds for tissue engineering. This review also discusses the potential advantages and limitations for using the powder bed fusion 3D-printing technology in terms of precision, customization, and cost effectiveness. In addition, it highlights the current challenges and prospects of the powder bed fusion 3D-printing technology. This work offers valuable insights for researchers engaged in the field, aiming to contribute to the advancement of the powder bed fusion 3D-printing technology in the context of precision manufacturing for biomedical applications.

Bioactivity, Cytotoxicity, and Tribological Studies of Nickel-Free Austenitic Stainless Steel Obtained via Powder Metallurgy Route.

In the present study, the bioactivity, cytotoxicity, and tribological properties of a nickel-free austenitic stainless steel produced via the mechanical alloying of elemental iron, chromium, and manganese nitride powders following by hot isostatic pressing was investigated. Powders after 90 h of mechanical alloying were consolidated via hot isostatic pressing at 1150 °C (1425 K) and heat treated at 1175 °C (1448 K) for 1 h in a vacuum with furnace cooling. Tribological tests were performed to determine the resistance of the as-received nickel-free steel. It was noticed that applying heat treatment after hot isostatic pressing decreases the average friction coefficient and wear rate of the austenitic steel. An immersion test in a simulated body fluid for 28 days at 37 ± 1 °C has been used to determine the biocompatibility of the tested material. The SEM-EDS analysis allowed us to characterise the morphology of the films and the elements of the steel on the thin-film layer. Elements typical of apatite (calcium and phosphorus) were detected on the surface of the sample. Cellular toxicity tests showed no significant toxic side effects for Saos-2 human osteosarcoma cells and the number of Saos-2 human osteosarcoma cells on the nickel-free steel was greater than on the 316LV grade steel.

Formation and Microstructural Evolution of Ferritic ODS Steel Powders during Mechanical Alloying.

Ferritic ODS steel elemental powder compositions with various Zr content (0.3-1.0 wt.%), ground in a Pulverisette 6 planetary ball mill, were extensively studied by X-ray diffraction line profile analysis, microscopic observations, microhardness testing and particle size measurements. A characteristic three-stage process of flattening the soft powders, formation of convoluted lamellae and, finally, formation of nanocrystalline grains was observed. In order to quantify the microstructural properties, expressed mainly in terms of crystallite size and dislocation density, a methodology for detailed and accurate microstructure analysis of nanosized and severely deformed materials was proposed by the Whole Powder Pattern Modelling (WPPM) approach. In the case of the proposed ODS alloy composition, the overlapping of Fe and Cr Bragg reflections makes the microstructure analysis certainly more complicated. The results showed that the microstructure of powders evolved towards the nanocrystalline state consisting of fine (diameter of ~15 nm) and narrowly dispersed domains, with extensive dislocation density exceeding 1016 m-2.

Metallic Strontium as a Precursor of the Al2O3/SrCO3 Xerogels Obtained by the One-Pot Sol-Gel Method.

Two series of binary xerogel systems of Sr/Al with molar ratios of 0.1, 0.25, 0.5, and 1.0 were synthesized by the sol-gel technique with metallic strontium component as a precursor. The influence of the metallic precursor on the properties of the final xerogel was determined. The properties of the gels were determined on the basis of X-ray powder diffraction (XRD), thermogravimetric analysis (TGA), low temperature nitrogen adsorption, transmission, and scanning electron microscopy with Energy Dispersive X-ray Spectroscopy (TEM, SEM, and SEM/EDS). The Al2O3/SrCO3 xerogels were tested as supports for platinum catalysts. Hydrogen chemisorption was used to determine the platinum dispersion of the Pt/Al2O3-SrCO3 systems. The original method of synthesis allows to obtain highly dispersed and stable strontium carbonate phases that allow for obtaining a high (42-50%) dispersion of platinum nanoparticles.

Mechanical and Thermal Properties of Polylactide (PLA) Composites Modified with Mg, Fe, and Polyethylene (PE) Additives.

In this article, polylactic acid-based composites reinforced with 5% of polyethylene, iron, and magnesium powders were prepared by extrusion and compressed under the pressure of about 10 MPa and characterized. These composites were mechanically, thermally, and morphologically evaluated. It was found, compared to the pure polylactic acid (PLA), an improvement in tensile strength (both σ and YS0.2) was obtained for the composite with the iron powder addition, while the magnesium powder slightly improved the ductility of the composite material (from 2.0 to 2.5%). Degradation studies of these composites in the 0.9% saline solution over a period of 180 days revealed changes in the pH of the solution from acidic to alkaline, in all samples. The most varied mass loss was observed in the case of the PLA-5%Mg sample, where initially the sample mass increased (first 30 days) then decreased, and after 120 days, the mass increased again. In the context of degradation phenomenon of the tested materials, it turns out that the most stable is the PLA composite with the Fe addition (PLA-5%Fe), with highest tensile strength and hardness.

Microstructure, Mechanical, and Corrosion Properties of Ni-Free Austenitic Stainless Steel Prepared by Mechanical Alloying and HIPping.

An influence of the powder metallurgy route on the phase structure, mechanical properties, and corrosion resistance of Fe-18%Cr-12%Mn-N nickel-free austenitic stainless steel as a potential material for medical applications were studied. The powder was mechanically alloyed in a high purity nitrogen atmosphere for 90 h followed by Hot Isostatic Pressing at 1150 °C (1423 K) and heat treatment at 1175 °C (1423 K) for 1 h in a vacuum with furnace cooling and water quenching. More than 96% of theoretical density was obtained for the samples after Hot Isostatic Pressing that had a direct influence on the tensile strength of the tested samples (Ultimate Tensile Strength is 935 MPa) with the total elongation of 0.5%. Heat treatment did not affect the tensile strength of the tested material, however, an elongation was improved by up to 3.5%. Corrosion properties of the tested austenitic stainless steel in various stages of the manufacturing process were evaluated applying the anodic polarization measurements and compared with the austenitic 316LV stainless steel. In general, the heat treatment applied after Hot Isostatic Pressing improved the corrosion resistance. The Hot Isostatic Pressing sample shows dissolution, while heat treatment causes a passivity range, the noblest corrosion potential, and lower current density of this sample.