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Enhancement of tribological properties and characteristic of polymer matrix composite (UHMWPE reinforced with short fibres of polyester) for Total Disc Replacement (TDR)

Obaid M. N., Radhi S. H.

Journal of Achievements in Materials and Manufacturing Engineering

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2020

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Vol. 102, nr 2

55--65

EN

Purpose: The number of people suffering from Degenerative Disc Disease (DDD) is increasing. The disease causes heavy pain and restrict a number of day-to-day life activities. In extreme cases, the degraded disc is removed under total disc replacement which is usually made up of Ultra-High Molecular Weight Polyethylene (UHMWPE). The material has astounding biocompatible characteristics mechanical properties and wear resistance. However, these characteristics are insufficient in arthroplasty application. Therefore, research investigations are ongoing to improve tribological properties through reinforcement that may result in a composite material of UHMWPE. Thus the current study is aimed at reinforcing UHMWPE with short fibres of polyesters to enhance the tribological properties and surface characteristic so as to improve wear resistance and nourish the fibroblast cells on synthetic disc. Design/methodology/approach: The researcher prepared UHMWPE composite material, reinforced with different weight fractions of short polyester fibres (2, 4, 6, 8 and 10% following hot press method. Further pin-on-disc device was used to study the tribological properties (coefficient of friction and volume of wear). The study tested surface roughness and surface characteristics by atomic force microscopy (AFM) device, hardness by shore D device, contact angle to study the effect of polyester short fibres on wettability of UHMWPE surface and tested the thermal properties and crystalline degree using Differential Scanning Calorimetry measurement (DSC) device. Findings: The results infer that the wear resistance got improved when using 2% w.t polyester though it got decreased initially. However, the value was still more than neat UHMWPE. There was a decrease observed in coefficient of friction, but after 4 w.t% polyester, the coefficient of friction got increased due to increasing percentage of fibres which make it harder and stiff compared to UHMWPE. There was a decline observed in surface roughness due to alignment of the fibres with smooth surface. The contact angle got increased in a moderate range while the roughness enhanced the growth of fibroblast cell. The hardness of composite material got increased, because the fibres turned stiffer and harder than the matrix. DSC results infer the improvements in thermal stability due to high thermal properties of polyester fibres compared to UHMWPE. The degree of crystallinity got increased which in turn enhanced wear resistance, especially at 6 w.t % polyester fibres. There was a mild increase observed in density since the density of polyester is higher than polymer. Research limitations/implications: The major challenge was the dispersion of fibres. Uniform distribution of fibres within the matrix (UHMWPE) was achieved through two steps of mixing processes such as mechanical mixture and twin extruder. In future studies, fatigue tests must be conducted to study the behaviour of prepared composite materials under fatigue cycle. Practical implications: A significant objective is how to connect among different properties to obtain good improvement in tribological and surface properties so as to enhance wear resistance and growth of fibrolase cells. Originality/value: In this study, polymeric short fibres were used as reinforcement with polymeric matrix to enhance the wettability of fibres with matrix. In this way, the bonding among them got increased which supports the tribological, surface, and crystalline behaviour.

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Effect of selective laser melting technology on the tribological properties of the prototype of intervertebral disc endoprothesis

Mróz A., Wiśniewski T., Skalski K.

Inżynieria Powierzchni

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2016

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nr 2

24--30

PL

Podjęto pracę nad zaprojektowaniem nowej konstrukcji endoprotezy krążka międzykręgowego odcinka lędźwiowego kręgosłupa, której komponenty metalowe wykonano ze stopu CoCrMo przy zastosowaniu technologii selektywnego topienia laserowego (SLM). Do badań porównawczych zostały wytworzone endoprotezy metodą obróbki skrawaniem z zastosowaniem obrabiarek sterowanych numerycznie (CNC). Wykonane prototypy poddano testom tribologicznym z wykorzystaniem symulatora kręgosłupa SBT-03.1. Celem pracy było określenie potencjału technologii SLM w procesie wytwarzania elementów endoprotez krążka międzykręgowego oraz określenie wpływu tej technologii na opory tarcia oraz ilość generowanych produktów zużycia.

EN

Work on the design of a new construction of intervertebral disc prosthesis of the lumbar spine has been started; the metal components of this endoprosthesis have been manufactured of CoCrMo alloy using the technology of selective laser melting (SLM). For comparative studies, the endoprostheses have been manufactured by machining with the use of numerically controlled machine tools (CNC). The fabricated prototypes have undergone the tribological tests using the SBT-03.1 spine simulator. The aim of the study was to determine the potential of SLM technology in the fabrication process of the elements of intervertebral disc endoprosthesis and to determine the impact of this technology on friction resistance and the amount of generated wear debris.

3

New lumbar disc endoprosthesis applied to the patient’s anatomic features

Mróz A., Skalski K., Walczyk W.

Acta of Bioengineering and Biomechanics

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2015

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Vol. 17, no. 2

25--34

EN

Purpose: The paper describes the process of designing, manufacturing and design verification of the intervertebral of a new structure of lumbar disc endoprosthesis – INOP/LSP.1101. Methods: Modern and noninvasive medical imagining techniques, make it possible to record results of tests in a digital form, which creates opportunities for further processing. Mimics Innovation Suite software generates three-dimensional virtual models reflecting the real shape and measurements of components of L4-L5 spinal motion segment. With the use of 3D Print technique, physical models of bone structures of the mobile segment of the spine as well as the INOP/LSP.1101 endoprosthesis model were generated. A simplified FEA analysis of stresses in the endoprosthesis was performed to evaluate the designed geometries and materials of the new structure. Results: The endoprosthesis prototype was made of Co28Cr6Mo alloy with the use of selective laser technology. The prototypes were subject to tribological verification with the use of the SBT-03.1 spine simulator. Conclusions: The structure of the endoprosthesis ensures a full reflection of its kinematics, full range of mobility of the motion segment in all anatomical planes as well as restoration of a normal height of the intervertebral space and curvature of the lordosis. The results of the tribological tests confirmed that SLM technology has the potential for production of the human bone and jointendoprostheses.

4

The accuracy of the reproduction of the lumbar spine elements following CT and MRI projections

Kroczak P., Skalski K., Nowakowski A., Mróz A.

Archive of Mechanical Engineering

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2014

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Vol. LXI, nr 4

523--538

EN

The paper presents an analysis of factors influencing the accuracy of reproduction of geometry of the vertebrae and the intervertebral disc of the lumbar motion segment for the purpose of designing of an intervertebral disc endoprosthesis. In order to increase the functionality of the new type of endoprostheses by a better adjustment of their structure to the patient’s anatomical features, specialist software was used allowing the processing of the projections of the diagnosed structures. Recommended minimum values of projection features were determined in order to ensure an effective processing of the scanned structures as well as other factors affecting the quality of the reproduction of 3D model geometries. Also, there were generated 3D models of the L4-L5 section. For the final development of geometric models for disc and vertebrae L4 and L5 there has been used smoothing procedure by cubic free curves with the NURBS technique. This allows accurate reproduction of the geometry for the purposes of identification of a spatial shape of the surface of the vertebrae and the vertebral disc and use of the model for designing of a new endoprosthesis, as well as conducting strength tests with the use of finite elements method.

PL

W artykule przedstawiono analizę czynników, które wpływają na dokładność odwzorowania geometrii kręgów i krążka międzykręgowego segmentu ruchowego kręgosłupa lędźwiowego, na potrzeby projektowania endoprotezy krążka międzykręgowego. W celu zwiększenia funkcjonalności nowego typu endoprotez poprzez lepsze dopasowanie ich konstrukcji do cech anatomicznych pacjenta, wykorzystywano specjalistyczne oprogramowanie, które umożliwiło przetwarzanie projekcji zdiagnozowanych struktur. Zgromadzone dane medyczne, pochodzace z projekcji tomografii komputerowej oraz rezonansu magnetycznego zostały opracowane i zestawione w utworzonej bazie danych. Poszczególne zbiory różniły się między sobą właściwościami (rozdzielczością, wielkością pojedynczego piksela, liczbą rastrów, odstępem pomiędzy rastrami oraz grubością rastrów). Na ich podstawie wygenerowano trójwymiarowe modele. Określono zalecane wartości minimalne cech projekcji, które zapewniają efektywne przetwarzanie skanowanych struktur oraz inne czynniki wpływające na jakość odwzorowania geometrii modeli 3D. Do końcowego opracowania modeli geometrycznych krążka oraz kręgów L4 i L5 wykorzystano procedurę wygładzania poprzez kubiczne krzywe swobodne techniką NURBS. Dzięki temu możliwe jest dokładne odwzorowanie geometrii w celu identyfikacji przestrzennego kształtu powierzchni kręgów i krążka międzykręgowego oraz wykorzystania modelu do zaprojektowania nowej endoprotezy, a także do przeprowadzenia badań wytrzymałościowych metodą elementów skończonych.