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Investigation of porosity behavior in SLS polyamide-12 samples using ex-situ X-ray computed tomography

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Ziółkowski G. , Grochowska E. , Kęszycki D. , Gruber P. , Hoppe V. , Szymczyk-Ziółkowska P. , Kurzynowski T.

tom Vol. 39, No. 3

436--445

The paper presents a detailed description of the method of carrying out static tensile tests in ex-situ X-ray computed tomography (XCT) conditions. The study compares samples manufactured with the use of additive technology in two orientations, horizontally and vertically, which correspond to the in-layer and between-layer sintering mechanisms. Both the fracture mechanism and porosity behavior differed significantly for the two manufacturing directions. The conducted analysis made it possible to compare the changes in porosity, the number of pores, and also their diameters and shape before and after the tensile test. This allows for in-depth identification and better understanding of the phenomena occurring during the static tensile test of polyamide-12 samples manufactured using selective laser sintering (SLS) technology.

Advancements in Maxillofacial Reconstruction: Design and Manufacturing Using Electron Beam Powder Bed Fusion (PBFEB/M)

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Szymczyk-Ziółkowska P. , Rusińska M. , Ziółkowski G. , Kobiela K. , Sekuła K. , Kęszycki D. , Miner-Kordasiewicz A.

tom Vol. 20, no. 1

49--61

Objective: Maxillofacial injuries often necessitate complex reconstructive surgeries, requiring the design and fabrication of patient-specific implants (PSIs) to restore functionality and aesthetics. A 32-year-old male patient, who sustained a mandible injury, served as a case study. Methods: This study presents advancements in maxillofacial reconstruction through the application of Electron Beam Powder Bed Fusion (PBF-EB/M), an additive manufacturing (AM) technique, in the creation of personalized jaw implants. CT scans were processed to develop a 3-D model of the patient's tissues, and Finite Element Analysis (FEA) was employed to assess mechanical behaviour. Results: The PSI, manufactured from a Ti6Al4V ELI alloy, exhibited suitable mechanical properties and biocompatibility. This work presents a workflow that clarifies the principles of designing, verifying and manufacturing PSIs for maxillofacial reconstruction. Conclusions: By integrating advanced imaging techniques, FEA simulations, and AM technologies, along with post-processing using CAM tools, the feasibility of producing personalized medical devices with modern manufacturing methods that offer enhanced design flexibility can be assessed. This includes highlighting both the potential benefits and challenges of the proposed approach.

Corrosion resistance characteristics of a Ti-6Al-4V ELI alloy fabricated by electron beam melting after the applied post-process treatment methods

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Szymczyk-Ziółkowska P. , Hoppe V. , Gąsiorek J. , Rusińska M. , Kęszycki D. , Szczepański Ł. , Dudek-Wicher R. , Detyna J.

2021

tom Vol. 41, no. 4

1575--1588

Post-process modifications in the form of Hot Isostatic Pressing or surface treatment methods such as sandblasting ormachining have been widely used in the case of improving the quality of elements manufactured with the use of EBM (Electron Beam Melting). The corrosion resistance of titanium alloys for medical applications is a key and critical aspect for the use of personalized components as implants, especially when investigating the issue of additive manufacturing. This paper presents the results of research on the influence of HIP processing on the functional properties of the material produced with the use of EBM, considering the aspect of reconstructive medicine. Both the influence of surface modification and the influence of post-process treatment on microstructural, mechanical, and corrosion properties were investigated. A wide range of research has been carried out using scanning and transmission electron microscopy methods, in combination with three-point static bending tests and performing corrosion tests using potentiodynamic polarization and electrochemical spectroscopic impedance (EIS) in Hank‘s solution. The results showed that HIP treatment has a positive effect on the corrosive properties of the material in terms of increased corrosion resistance compared to materials not subjected to this type of post-process treatment. This fact is also related to the change of the alloy microstructure and the change of mechanical properties towards increased plasticity. In the case of the production of personalized implants with the use of EBM, it is worth considering the benefits of the HIP.