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Article

Fabrication and Optimisation of Ti-6Al-4V Lattice-Structured Total Shoulder Implants Using Laser Additive Manufacturing

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School of Engineering, University of Birmingham, Birmingham B152TT, UK
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School of Engineering, Technology, and Design, Canterbury Christ Church University, Canterbury CT1 1QU, UK
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Department of Industrial Engineering, Arab Academy for Science Technology and Maritime, Alexandria 21599, Egypt
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College of Engineering, Imam Mohammad Ibn Saud Islamic University, Riyadh 11564, Saudi Arabia
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Department of Production Engineering and Mechanical Design, Tanta University, Tanta 31512, Egypt
*
Author to whom correspondence should be addressed.
Academic Editor: Joseph Sanderson
Materials 2022, 15(9), 3095; https://doi.org/10.3390/ma15093095
Received: 3 April 2022 / Revised: 17 April 2022 / Accepted: 21 April 2022 / Published: 25 April 2022
(This article belongs to the Special Issue Advanced Laser Microfabrication)
This work aimed to study one of the most important challenges in orthopaedic implantations, known as stress shielding of total shoulder implants. This problem arises from the elastic modulus mismatch between the implant and the surrounding tissue, and can result in bone resorption and implant loosening. This objective was addressed by designing and optimising a cellular-based lattice-structured implant to control the stiffness of a humeral implant stem used in shoulder implant applications. This study used a topology lattice-optimisation tool to create different cellular designs that filled the original design of a shoulder implant, and were further analysed using finite element analysis (FEA). A laser powder bed fusion technique was used to fabricate the Ti-6Al-4V test samples, and the obtained material properties were fed to the FEA model. The optimised cellular design was further fabricated using powder bed fusion, and a compression test was carried out to validate the FEA model. The yield strength, elastic modulus, and surface area/volume ratio of the optimised lattice structure, with a strut diameter of 1 mm, length of 5 mm, and 100% lattice percentage in the design space of the implant model were found to be 200 MPa, 5 GPa, and 3.71 mm−1, respectively. The obtained properties indicated that the proposed cellular structure can be effectively applied in total shoulder-replacement surgeries. Ultimately, this approach should lead to improvements in patient mobility, as well as to reducing the need for revision surgeries due to implant loosening. View Full-Text
Keywords: additive manufacturing; laser powder bed fusion; lattice optimisation; Young’s modulus; orthopaedic implants additive manufacturing; laser powder bed fusion; lattice optimisation; Young’s modulus; orthopaedic implants
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MDPI and ACS Style

Bittredge, O.; Hassanin, H.; El-Sayed, M.A.; Eldessouky, H.M.; Alsaleh, N.A.; Alrasheedi, N.H.; Essa, K.; Ahmadein, M. Fabrication and Optimisation of Ti-6Al-4V Lattice-Structured Total Shoulder Implants Using Laser Additive Manufacturing. Materials 2022, 15, 3095. https://doi.org/10.3390/ma15093095

AMA Style

Bittredge O, Hassanin H, El-Sayed MA, Eldessouky HM, Alsaleh NA, Alrasheedi NH, Essa K, Ahmadein M. Fabrication and Optimisation of Ti-6Al-4V Lattice-Structured Total Shoulder Implants Using Laser Additive Manufacturing. Materials. 2022; 15(9):3095. https://doi.org/10.3390/ma15093095

Chicago/Turabian Style

Bittredge, Oliver, Hany Hassanin, Mahmoud Ahmed El-Sayed, Hossam Mohamed Eldessouky, Naser A. Alsaleh, Nashmi H. Alrasheedi, Khamis Essa, and Mahmoud Ahmadein. 2022. "Fabrication and Optimisation of Ti-6Al-4V Lattice-Structured Total Shoulder Implants Using Laser Additive Manufacturing" Materials 15, no. 9: 3095. https://doi.org/10.3390/ma15093095

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