Abstract
A key advantage of additive manufacturing (AM) is that it allows the fabrication of lattice structures for customized biomedical implants with high performance. This paper presents the use of statistical approaches in design optimization of additively manufactured titanium lattice structures for biomedical implants. Design of experiments using response surface and analysis of variance was carried out to study the effect design parameters on the properties of the AM lattice structures such as ultimate compression strength, specific compressive strength, elastic modulus, and porosity. In addition, the lattice dimensions were optimized to fabricate a diamond cellular structure with properties that match human bones. The study found that the length of a diamond-shaped unit cell strut is the most significant design parameter. In particular, the porosity of the unit cell increases as the strut length increases, while it had a significant reverse effect on the specific compressive strength, elastic modulus, and ultimate compression strength. On the other hand, increasing the orientation angle was found to reduce both the specific compressive strength and modulus of elasticity of the lattice structure. An optimized lattice structure with strut diameter of 0.84 mm, length of 3.29 mm, and orientation angle of 47° was shown to have specific compressive strength, elastic modulus, ultimate compression strength, and porosity of 37.8 kN m/kg, 1 GPa, 49.5 MPa, and 85.7%, respectively. A cellular structure with the obtained properties could be effectively applied for trabecular bone replacement surgeries.
Similar content being viewed by others
References
Kang D, Park S, Son Y, Yeon S, Kim SH, Kim I (2019) Multi-lattice inner structures for high-strength and light-weight in metal selective laser melting process. Mater Des 175:107786
Iwase A, Hori F (2020) Modification of lattice structures and mechanical properties of metallic materials by energetic ion irradiation and subsequent thermal treatments. Quantum Beam Sci 4:17
Cosma C, Kessler J, Gebhardt A, Campbell I, Balc N (2020) Improving the mechanical strength of dental applications and lattice structures SLM processed. Materials 13:905
Sienkiewicz J, Płatek P, Jiang F, Sun X, Rusinek A (2020) Investigations on the mechanical response of gradient lattice structures manufactured via SLM. Metals 10:213
Hassanin H, Modica F, El-Sayed MA, Liu J, Essa K (2016) Manufacturing of Ti-6Al-4V micro-implantable parts using hybrid selective laser melting and micro-electrical discharge machining. Adv Eng Mater 18(9):1544–1549
Maskery I, Aremu A, Parry L, Wildman R, Tuck C, Ashcroft I (2018) Effective design and simulation of surface-based lattice structures featuring volume fraction and cell type grading. Mater Des 155:220–232
Narkhede S, Sur A, Darvekar S (2019) Applications, manufacturing and thermal characteristics of micro-lattice structures: current state of the art. Eng J 23:419–431. https://doi.org/10.4186/ej.2019.23.6.419
Rashed M, Ashraf M, Mines R, Hazell PJ (2016) Metallic microlattice materials: a current state of the art on manufacturing, mechanical properties and applications. Mater Des 95:518–533
Maldovan M, Ullal CK, Jang J-H, Thomas EL (2007) Sub-micrometer scale periodic porous cellular structures: microframes prepared by holographic interference lithography. Adv Mater 19:3809–3813. https://doi.org/10.1002/adma.200700811
Zhu Z, Hassanin H, Jiang K (2010) A soft moulding process for manufacture of net-shape ceramic microcomponents. Int J Adv Manuf Technol 47:147–152. https://doi.org/10.1007/s00170-008-1864-z
Hassanin H, Jiang K (2011) Multiple replication of thick PDMS micropatterns using surfactants as release agents. Microelectron Eng 88:3275–3277. https://doi.org/10.1016/j.mee.2011.06.027
Hassanin H, Jiang K (2009) Fabrication of Al2O3/SiC composite microcomponents using non-aqueous suspension. Adv Eng Mater 11:101–105. https://doi.org/10.1002/adem.200800158
Hassanin H, Jiang K (2013) Net shape manufacturing of ceramic micro parts with tailored graded layers. J Micromech Microeng 24:015018. https://doi.org/10.1088/0960-1317/24/1/015018
Hassanin H, Jiang K (2013) Fabrication and characterization of stabilised zirconia micro parts via slip casting and soft moulding. Scr Mater 69:433–436. https://doi.org/10.1016/j.scriptamat.2013.05.004
Hassanin H, Jiang K (2010) Functionally graded microceramic components. Microelectron Eng:87, 1610–1613. https://doi.org/10.1016/j.mee.2009.10.044
Hassanin H, Jiang K (2009) Alumina composite suspension preparation for softlithography microfabrication. Microelectron Eng 86:929–932. https://doi.org/10.1016/j.mee.2008.12.067
Hassanin H, Jiang K (2010) Optimized process for the fabrication of zirconia micro parts. Microelectron Eng 87:1617–1619. https://doi.org/10.1016/j.mee.2009.10.037
Essa K, Modica F, Imbaby M, El-Sayed MA, ElShaer A, Jiang K, Hassanin H (2017) Manufacturing of metallic micro-components using hybrid soft lithography and micro-electrical discharge machining. Int J Adv Manuf Technol 91:445–452
Hassanin H, Essa K, Qiu C, Abdelhafeez Ali M, Adkins Nicholas JE, Attallah Moataz M (2017) Net-shape manufacturing using hybrid selective laser melting/hot isostatic pressing. Rapid Prototyp J 23:720–726. https://doi.org/10.1108/RPJ-02-2016-0019
Qiu C, Adkins NJE, Hassanin H, Attallah MM, Essa K (2015) In-situ shelling via selective laser melting: modelling and microstructural characterisation. Mater Des 87:845–853. https://doi.org/10.1016/j.matdes.2015.08.091
Hassanin H, Finet L, Cox SC, Jamshidi P, Grover LM, Shepherd DET, Addison O, Attallah MM (2018) Tailoring selective laser melting process for titanium drug-delivering implants with releasing micro-channels. Addit Manuf 20:144–155. https://doi.org/10.1016/j.addma.2018.01.005
Klippstein H, Hassanin H, Diaz De Cerio Sanchez A, Zweiri Y, Seneviratne L (2018) Additive manufacturing of porous structures for unmanned aerial vehicles applications. Adv Eng Mater 20:1800290. https://doi.org/10.1002/adem.201800290
Sabouri A, Yetisen AK, Sadigzade R, Hassanin H, Essa K, Butt H (2017) Three-dimensional microstructured lattices for oil sensing. Energy Fuel 31:2524–2529. https://doi.org/10.1021/acs.energyfuels.6b02850
Klippstein H, Diaz De Cerio Sanchez A, Hassanin H, Zweiri Y, Seneviratne L (2018) Fused deposition modeling for unmanned aerial vehicles (UAVs): a review. Adv Eng Mater 20:1700552. https://doi.org/10.1002/adem.201700552
Galatas A, Hassanin H, Zweiri Y, Seneviratne L (2018) Additive manufactured sandwich composite/ABS parts for unmanned aerial vehicle applications. Polymers (Basel) 10:1262
Tan C, Li S, Essa K, Jamshidi P, Zhou K, Ma W, Attallah MM (2019) Laser powder bed fusion of Ti-rich TiNi lattice structures: process optimisation, geometrical integrity, and phase transformations. Int J Mach Tools Manuf 141:19–29. https://doi.org/10.1016/j.ijmachtools.2019.04.002
Hassanin H, Abena A, Elsayed MA, Essa K (2020) 4D printing of NiTi auxetic structure with improved ballistic performance. Micromachines 11:745
Penchev P, Bhaduri D, Carter L, Mehmeti A, Essa K, Dimov S, Adkins NJE, Maillol N, Bajolet J, Maurath J, Jurdeczka U (2019) System-level integration tools for laser-based powder bed fusion enabled process chains. J Manuf Syst 50:87–102. https://doi.org/10.1016/j.jmsy.2018.12.003
Li Y, Feng Z, Hao L, Huang L, Xin C, Wang Y, Bilotti E, Essa K, Zhang H, Li Z, Yan F, Peijs T (2020) A review on functionally graded materials and structures via additive manufacturing: from multi-scale design to versatile functional properties. Adv Mater Technol 5:1900981. https://doi.org/10.1002/admt.201900981
Li Y, Feng Z, Huang L, Essa K, Bilotti E, Zhang H, Peijs T, Hao L (2019) Additive manufacturing high performance graphene-based composites: a review. Compos A Appl Sci Manuf 124:105483. https://doi.org/10.1016/j.compositesa.2019.105483
Rehme O, Emmelmann C (2006) Rapid manufacturing of lattice structures with selective laser melting. SPIE 6107:192–203
Challis VJ, Xu X, Zhang LC, Roberts AP, Grotowski JF, Sercombe TB (2014) High specific strength and stiffness structures produced using selective laser melting. Mater Des 63:783–788
Elsayed M, Ghazy M, Youssef Y, Essa K (2019) Optimization of SLM process parameters for Ti6Al4V medical implants. Rapid Prototyp J 25:433–447
Hassanin H, Al-Kinani AA, ElShaer A, Polycarpou E, El-Sayed MA, Essa K (2017) Stainless steel with tailored porosity using canister-free hot isostatic pressing for improved osseointegration implants. J Mater Chem B 5:9384–9394
Wang X, Xu S, Zhou S, Xu W, Leary M, Choong P, Qian M, Brandt M, Xie YM (2016) Topological design and additive manufacturing of porous metals for bone scaffolds and orthopaedic implants: a review. Biomaterials 83:127–141
Sing SL, Yeong WY, Wiria FE, Tay B (2016) Characterization of titanium lattice structures fabricated by selective laser melting using an adapted compressive test method. Exp Mech 56:735–748
Brenne F, Niendorf T, Maier H (2013) Additively manufactured cellular structures: impact of microstructure and local strains on the monotonic and cyclic behavior under uniaxial and bending load. J Mater Process Technol 213:1558–1564
Salem H, Carter L, Attallah M, Salem H (2019) Influence of processing parameters on internal porosity and types of defects formed in Ti6Al4V lattice structure fabricated by selective laser melting. Mater Sci Eng A 767:138387
Wauthle R, Vrancken B, Beynaerts B, Jorissen K, Schrooten J, Kruth J-P, Van Humbeeck J (2015) Effects of build orientation and heat treatment on the microstructure and mechanical properties of selective laser melted Ti6Al4V lattice structures. Addit Manuf 5:77–84
Mazur M, Leary M, Sun S, Vcelka M, Shidid D, Brandt M (2016) Deformation and failure behaviour of Ti-6Al-4V lattice structures manufactured by selective laser melting (SLM). Int J Adv Manuf Technol 84:1391–1411
Sing SL, Wiria FE, Yeong WY (2018) Selective laser melting of lattice structures: a statistical approach to manufacturability and mechanical behavior. Robot Comput Integr Manuf 49:170–180
Hader R, Park SH (1978) Slope-rotatable central composite designs. Technometrics 20:413–417
Tamburrino F, Graziosi S, Bordegoni M (2018) The design process of additively manufactured mesoscale lattice structures: a review. J Comput Inf Sci Eng 18. https://doi.org/10.1115/1.4040131
Essa K, Hassanin H, Attallah MM, Adkins NJ, Musker AJ, Roberts GT, Tenev N, Smith M (2017) Development and testing of an additively manufactured monolithic catalyst bed for HTP thruster applications. Appl Catal A Gen 542:125–135. https://doi.org/10.1016/j.apcata.2017.05.019
Hassanin H, Alkendi Y, Elsayed M, Essa K, Zweiri Y (2020) Controlling the properties of additively manufactured cellular structures using machine learning approaches. Adv Eng Mater 22(3):1901338
Essa K, Sabouri A, Butt H, Basuny FH, Ghazy M, El-Sayed MA (2018) Laser additive manufacturing of 3D meshes for optical applications. PloS one 13:e0192389
Liu F, Zhang DZ, Zhang P, Zhao M, Jafar S (2018) Mechanical properties of optimized diamond lattice structure for bone scaffolds fabricated via selective laser melting. Materials 11:374
Weißmann V, Wieding J, Hansmann H, Laufer N, Wolf A, Bader R (2016) Specific yielding of selective laser-melted Ti6Al4V open-porous scaffolds as a function of unit cell design and dimensions. Metals 6:166
Choy SY, Sun C-N, Leong KF, Wei J (2017) Compressive properties of Ti-6Al-4V lattice structures fabricated by selective laser melting: design, orientation and density. Addit Manuf 16:213–224
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
El-Sayed, M.A., Essa, K., Ghazy, M. et al. Design optimization of additively manufactured titanium lattice structures for biomedical implants. Int J Adv Manuf Technol 110, 2257–2268 (2020). https://doi.org/10.1007/s00170-020-05982-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-020-05982-8