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Open AccessArticle

Customized a Ti6Al4V Bone Plate for Complex Pelvic Fracture by Selective Laser Melting

by Di Wang 1,†, Yimeng Wang 1, Shibiao Wu 1, Hui Lin 1,†, Yongqiang Yang 1,*, Shicai Fan 2,†, Cheng Gu 2,†, Jianhua Wang 3,† and Changhui Song 1,†
1
School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510640, China
2
The Third Affiliated Hospital of Southern Medical University, Guangzhou 510600, China
3
Hospital of Orthopedics, Guangzhou General Hospital of Guangzhou Military Command, Guangzhou 510010, China
*
Author to whom correspondence should be addressed.
These authors contributed equally to this work.
Academic Editors: Wai Yee Yeong and Chee Kai Chua
Materials 2017, 10(1), 35; https://doi.org/10.3390/ma10010035
Received: 11 November 2016 / Revised: 16 December 2016 / Accepted: 29 December 2016 / Published: 4 January 2017
(This article belongs to the Special Issue 3D Printing for Biomedical Engineering)
In pelvic fracture operations, bone plate shaping is challenging and the operation time is long. To address this issue, a customized bone plate was designed and produced using selective laser melting (SLM) technology. The key steps of this study included designing the customized bone plate, metal 3D printing, vacuum heat treatment, surface post-processing, operation rehearsal, and clinical application and evaluation. The joint surface of the bone plate was placed upwards with respect to the build platform to keep it away from the support and to improve the quality of the joint surface. Heat conduction was enhanced by adding a cone-type support beneath the bone plate to prevent low-quality fabrication due to poor heat conductivity of the Ti-6Al-4V powder. The residual stress was eliminated by exposing the SLM-fabricated titanium-alloy bone plate to a vacuum heat treatment. Results indicated that the bone plate has a hardness of HV1 360–HV1 390, an ultimate tensile strength of 1000–1100 MPa, yield strength of 900–950 MPa, and an elongation of 8%–10%. Pre-operative experiments and operation rehearsal were performed using the customized bone plate and the ABC-made pelvic model. Finally, the customized bone plate was clinically applied. The intraoperative C-arm and postoperative X-ray imaging results indicated that the customized bone plate matched well to the damaged pelvis. The customized bone plate fixed the broken bone and guides pelvis restoration while reducing operation time to about two hours. The customized bone plate eliminated the need for preoperative titanium plate pre-bending, thereby greatly reducing surgical wounds and operation time. View Full-Text
Keywords: metal additive manufacturing; selective laser melting; bone plate; pelvic fracture; Ti-6Al-4V metal additive manufacturing; selective laser melting; bone plate; pelvic fracture; Ti-6Al-4V
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MDPI and ACS Style

Wang, D.; Wang, Y.; Wu, S.; Lin, H.; Yang, Y.; Fan, S.; Gu, C.; Wang, J.; Song, C. Customized a Ti6Al4V Bone Plate for Complex Pelvic Fracture by Selective Laser Melting. Materials 2017, 10, 35.

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