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Manufacturing of metal-polymer composites for medical applications

Dobrzańska-Danikiewicz A. D., Gaweł T. G., Karska M.

Archives of Materials Science and Engineering

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2018

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Vol. 89, nr 1

9--19

EN

Purpose: The purpose of the article is to present the design and fabrication methodology of metallic scaffolds, with the shape and dimensions defined by the designer, coated with a thin layer of polymer. Design/methodology/approach: The methodology proposed covers Computer Aided Materials Design (CAMD), fabrication of metallic scaffolds using a machine for Selective Laser Melting (SLM), the deposition of a thin layer of polymers onto scaffolds using coldwork and hot-work polymerisers, as well as mechanical finishing. The strength of the newly developed metal-polymer composites to three-point bending was examined and their fractures were viewed with SEM. Findings: A fabrication method of implants in the form of scaffolds coated with a thin layer of polymer with the dimensions and shape closely matching the losses in a patient’s hard and/or soft palate. Practical implications: After clinical tests, a metal-polymer implant may be a very beneficial alternative for patients with palate losses using traditional prostheses until now. Originality/value: The individualised implants of palate pieces in the form of scaffolds coated with a thin layer of polymer, submitted for patent protection, do not have their counterparts, which is representing their originality.

2

Individual implants of a loss of palate fragments fabricated using SLM equipment

Dobrzański L. A., Dobrzańska-Danikiewicz A., Gaweł T. G.

Journal of Achievements in Materials and Manufacturing Engineering

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2016

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Vol. 77, nr 1

24--30

EN

Purpose: The aim of the article is to present the new conception of design and manufacturing individual implants of a loss of palate fragments using Selective Laser Melting equipment. Design/methodology/approach: The designed virtual model of scaffolds have been produced in a process of selective laser melting (SLM). For their preparation titanium alloy powder - Ti6Al4V of suitable granulation and shape has been used. Thus obtained scaffolds have been observed in a scanning electron microscope. The structure of the pores is compatible with the shape of a designed unit cell. The outcarried EDS analysis has confirmed the chemical composition of the tested material. Findings: In the framework of research innovative porous biomimetic materials called scaffolds with the well-defined regular structure of open pores have been used. Virtual implant models have been made using Computer Aided Materials Design. They have the geometrical dimensions corresponding to a fragment of a loss of a human palate. Porous and regular structure with defined geometric dimensions and shape are designed in the form of the unit cell, which has then been subjected to the multiplication process. Practical implications: The scaffolds fabricated in the SLM process create conditions for their application as implants of a loss of palate fragments. Originality/value: Implants for the whole palate or its part, required due to mechanical injuries, tumorous diseases or cleft palate are original at the basis of a literature review.

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Ti6Al4V porous elements coated by polymeric surface layer for biomedical applications

Dobrzański L. A., Dobrzańska-Danikiewicz A. D., Gaweł T. G.

Journal of Achievements in Materials and Manufacturing Engineering

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2015

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Vol. 71, nr 2

53--59

EN

Purpose: The aim of the paper is to characterise titanium alloy Ti6Al4V coated by polymeric surface layer as a material for biomedical applications. The paper presents a Selective Laser Melting (SLM) method of fabrication of elements to be used as implants from Ti6Al4V powder. It was demonstrated that the metallic scaffolds created have strictly defined geometric dimensions of an object and open pores, and the pores are regular and repeat within the whole volume of the biomimetic element. Design/methodology/approach: The actual manufacturing process is preceded with creating a model of an element in the stl format that allows to present the element surface by means of a net of triangles. Once the shape is defined of a unit cell and its net parameters, i.e. height, depth and width, they are duplicated with appropriate mathematical algorithms as a result of which a strictly defined, densed and complicated structure of pores defined by a designer is created. Findings: Scanning electron microscopy was applied for showing the structure of pure scaffolds as well as composites made of Ti6Al4V scaffolds coated by polymeric surface layer. Microscope observations were performed using a SEM Zeiss Supra 35 equipped with EDS detectors for chemical composition analysis. Practical implications: Manufactured metal-polymer composites can be used in regenerative medicine as biomimetic implants. Originality/value: The characteristics of biomimetic composites, used in medicine as implants of a palate piece loss with strictly designed geometric shape and dimensions of the object and its strictly planed pores.

4

Selective Laser Sintering And Melting of Pristine Titanium and Titanium Ti6Al4V Alloy Powders and Selection of Chemical Environment for Etching of Such Materials

Dobrzański L. A., Dobrzańska-Danikiewicz A. D., Gaweł T. G., Achtelik-Franczak A.

Archives of Metallurgy and Materials

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2015

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Vol. 60, iss. 3A

2040--2045

EN

The aim of the investigations described in this article is to present a selective laser sintering and melting technology to fabricate metallic scaffolds made of pristine titanium and titanium Ti6Al4V alloy powders. Titanium scaffolds with different properties and structure were manufactured with this technique using appropriate conditions, notably laser power and laser beam size. The purpose of such elements is to replace the missing pieces of bones, mainly cranial and facial bones in the implantation treatment process. All the samples for the investigations were designed in CAD/CAM (3D MARCARM ENGINEERING AutoFab (Software for Manufacturing Applications) software suitably integrated with an SLS/SLM system. Cube-shaped test samples dimensioned 10×10×10 mm were designed for the investigations using a hexagon-shaped base cell. The so designed 3D models were transferred to the machine software and the actual rapid manufacturing process was commenced. The samples produced according to the laser sintering technology were subjected to chemical processing consisting of etching the scaffolds’ surface in different chemical mediums. Etching was carried out to remove the loosely bound powder from the surface of scaffolds, which might detach from their surface during implantation treatment and travel elsewhere in an organism. The scaffolds created were subjected to micro- and spectroscopic examinations

PL

Celem badań, opisanych w niniejszym artykule jest zaprezentowanie technologii selektywnego spiekania i topienia laserowego w celu wytworzenia metalowych scaffoldów z proszków: czystego tytanu oraz jego stopu Ti6Al4V. Techniką tą przy zastosowaniu odpowiednich warunków wytwarzania między innymi mocy lasera i wielkości plamki lasera wytworzono tytanowe scaffoldy o różnych własnościach i strukturze. Tego typu elementy mają za zadanie zastąpić brakujące fragmenty kości głównie kości szczękowo-twarzowych w procesie leczenia implantacyjnego. Wszystkie próbki do badań zaprojektowano w odpowiednio zintegrowanym z systemem SLS/SLM oprogramowaniem CAD/CAM (3D MARCARM ENGINEERING AutoFab, Software for Manufacturing Applications). Przy wykorzystaniu komórki bazowej o kształcie heksagonalnym zaprojektowano próbki do badań w kształcie sześcianu o wymiarach 10×10×10 mm. Tak zaprojektowane trójwymiarowe modele przetransportowano do oprogramowania maszyny gdzie rozpoczęto właściwy proces wytwarzania przyrostowego. Wykonane w technologii spiekania laserowego próbki poddano obróbce chemicznej polegającej na trawieniu powierzchni scaffoldów, w różnych ośrodkach chemicznych. Trawienie wykonano w celu usunięcia z powierzchni scaffoldów luźno związanego proszku, który mógłby podczas leczenia implantacyjnego oderwać się od ich powierzchni i przedostać się w inne miejsce organizmu. Wytworzone scaffoldy poddano badaniom mikro- i spektroskopowym.

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Fabrication Of Scaffolds From Ti6Al4V Powders Using The Computer Aided Laser Method

Dobrzański L. A., Dobrzańska-Danikiewicz A. D., Malara P., Gaweł T. G., Dobrzański L. B., Achtelik-Franczak A.

Archives of Metallurgy and Materials

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2015

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Vol. 60, iss. 2A

1065--1070

EN

The aim of the research, the results of which are presented in the paper, is to fabricate, by Selective Laser Melting (SLM), a metallic scaffold with Ti6Al4V powder based on a virtual model corresponding to the actual loss of a patient’s craniofacial bone. A plaster cast was made for a patient with a palate recess, and the cast was then scanned with a 3D scanner to create a virtual 3D model of a palate recess, according to which a 3D model of a solid implant was created using specialist software. The virtual 3D solid implant model was converted into a 3D porous implant model after designing an individual shape of the unit cell conditioning the size and three-dimensional shape of the scaffold pores by multiplication of unit cells. The data concerning a virtual 3D porous implant model was transferred into a selective laser melting (SLM) device and a metallic scaffold was produced from Ti6Al4V powder with this machine, which was subjected to surface treatment by chemical etching. An object with certain initially adopted assumptions, i.e. shape and geometric dimensions, was finally achieved, which perfectly matches the patient bone recesses. The scaffold created was subjected to micro-and spectroscopic examinations.

PL

Celem badań, których wyniki zaprezentowano w artykule jest wytworzenie, metodą selektywnego topienia laserowego (SLM), scaffoldu metalowego z proszku Ti6Al4V na podstawie wirtualnego modelu odpowiadającego rzeczywistemu ubytkowi kości twarzoczaszki pacjenta. Od pacjenta z ubytkiem podniebienia pobierano wycisk gipsowy, który następnie zeskanowano za pomocą skanera 3D, w celu uzyskania wirtualnego modelu 3D ubytku podniebienia, na podstawie którego z użyciem specjalistycznego oprogramowania utworzono model 3D litego implantu. Po zaprojektowaniu indywidualnego kształtu komórki jednostkowej, determinującej wielkość i trójwymiarowy kształt porów scaffoldu, poprzez multiplikację komórek jednostkowych przekształcono wirtualny model 3D implantu litego w model 3D implantu porowatego. Dane dotyczące wirtualnego modelu 3D implantu porowatego przetransferowano do urządzenia służącego do selektywnego topienia laserowego (SLM) i z użyciem tej maszyny z proszku Ti6Al4V wytworzono metalowy scaffold, który poddano obróbce powierzchniowej poprzez trawienie chemiczne. Finalnie otrzymano obiekt o założonych na wstępie: kształcie i wymiarach geometrycznych, które idealnie odpowiadają ubytkowi kości pacjenta. Wytworzony scaffold poddano badaniom mikro i spektroskopowym.

6

Ti6Al4V titanium alloy used as a modern biomimetic material

Dobrzańska-Danikiewicz A. D., Gaweł T. G., Wolany W.

Archives of Materials Science and Engineering

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2015

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Vol. 76, nr 2

150--156

EN

Purpose: The principal aim of the article is to characterise titanium alloy Ti6Al4V as a biomimetic material. The work presents in particular the application of this alloy in regenerative/aesthetic medicine for implants of craniofacial elements against other its other applications in various branches of industry. The article presents a rapid manufacturing (RM) method of fabrication of elements to be used as implants from Ti6Al4V powder. It was demonstrated that the scaffolds created in Selective Laser Melting (SLM) have strictly defined geometric dimensions of an object and open pores, and the pores are regular and repeat within the whole volume of the object. Design/methodology/approach: Scanning electron microscopy was applied for showing the structure of innovative biomimetic materials made of Ti6Al4V powder. Findings: It was confirmed in SEM examinations that the structure of laser-sintered objects consists, within its entire volume, of regularly occurring pores with strictly specified geometric dimensions. Practical implications: Biomimetic materials can be used in regenerative/aesthetic medicine as implants. The purpose of the scaffolds produced is to enable the growth of soft tissue or bone tissue in craniofacial elements. Originality/value: Biomimetic materials can be used in regenerative/aesthetic medicine as implants. The purpose of the scaffolds produced is to enable the growth of soft tissue or bone tissue in craniofacial elements.