Search Results (685)

The cleanliness and functionalization of metal surfaces are critical factors to determining their performance in high-performance microelectronic packaging, reliable biomedical implants, advanced composite bonding, and other fields. Compared to traditional wet cleaning methods, plasma cleaning technology has emerged as a research hotspot in surface engineering due to its unique advantages, such as high efficiency and environmental friendliness. It operates under versatile conditions (e.g., power: tens of watts to several kilowatts; pressure: atmospheric to low vacuum; treatment time: seconds to minutes), enabling not only efficient contaminant removal but also targeted surface functionalization, including dramatically enhanced hydrophilicity (e.g., contact angles from >80° to <10°), significantly improved adhesion (e.g., up to 40% increase in bond strength), and modifications in surface roughness, corrosion resistance, and biocompatibility. This review systematically elaborates on the physical, chemical, and synergistic mechanisms of plasma cleaning technology as it acts on metal surfaces. It focuses on plasma cleaning applied to copper, aluminum, titanium and their respective alloys, as well as alloy steels, providing a detailed analysis of contaminant types, plasma cleaning methodologies, common challenges, surface functionalization responses, and subsequent functional applications. Furthermore, this review discusses the current challenges faced by plasma cleaning technology and offers perspectives on its future development directions. It aims to systematize the research progress in plasma cleaning of metal surfaces, thereby facilitating the transition of this technology towards large-scale industrial applications for metal surface functionalization. Full article

Background: Postoperative infections remain a major complication in spinal surgeries involving intersomatic screws, often compromising osseointegration and long-term implant stability. Questions/Purposes: This study evaluated a nanotextured titanium oxide surface with nanopillar-like morphology designed to reduce bacterial colonization while preserving mechanical integrity and promoting bone integration. Methods: Ti₆Al₄V screws were studied in three batches: control, passivated with HCl and acid mixture treatment to obtain nanotopographies on the surfaces. To create the nanotopographies, the screws were treated with a 1:1 (v/v) sulfuric acid–hydrogen peroxide solution for 2 h. Surface morphology, roughness, wettability, and surface energy were analyzed by SEM, confocal microscopy, and contact angle measurements. Corrosion and ion release were assessed electrochemically and by ICP-MS, respectively. Mechanical behavior, cytocompatibility, mineralization, and antibacterial efficacy were evaluated in vitro. Osseointegration was analyzed in rabbit tibiae after 21 days by histology and bone–implant contact (BIC). Results: The treatment produced uniform nanopillars (Ra = 0.12 µm) with increased hydrophilicity (49° vs. 102° control) and higher surface energy. Mechanical properties and fatigue resistance (~600 N, 10 million cycles) were unaffected. Corrosion currents and Ti ion release remained low. Nanopillar surfaces enhanced osteoblast adhesion and mineralization and reduced bacterial viability by >60% for most strains. In vivo, Bone Index Contact (BIC) was higher for nanopillars (52.0%) than for HCl-treated (43.8%) and control (40.1%) screws, showing a positive osseointegration trend (p > 0.005). Conclusions: The proposed acid-etching process generates a stable, scalable nanotopography with promising antibacterial and osteogenic potential while maintaining the alloy’s mechanical and chemical integrity. Clinical relevance: This simple, scalable, and drug-free surface modification offers a promising approach to reduce postoperative infections and promote bone integration in spinal implants. Full article

Titanium alloys are widely used for biomedical implants, but their performance is limited by wear, corrosion, and susceptibility to bacterial colonisation. To overcome these drawbacks, multilayer Ti–Cu oxide coatings were deposited on Ti6Al4V substrates using direct current magnetron sputtering. Two multilayer architectures (6 × 2 and 12 × 2 TiO₂/CuO bilayers) were fabricated and evaluated for their structural, mechanical, electrochemical, and biological properties. SEM/EDS and XRD confirmed well-adhered crystalline coatings consisting of rutile/anatase TiO₂ and monoclinic CuO with uniform elemental distribution. The coatings increased surface roughness, improved adhesion, and enhanced hardness by up to ~180% compared to uncoated Ti6Al4V alloy. Compared to the bare substrate, electrochemical testing in simulated body fluid showed higher corrosion resistance of both coated samples, but particularly for the 12 × 2 multilayers. Both architectures provided sustained Cu²⁺ release over seven days without a burst effect. In vitro biological testing showed that both multilayer coatings achieved over 96% inhibition of Gram-positive bacteria such as Staphylococcus aureus and Bacillus subtilis, while exhibiting moderate antibacterial effects against Gram-negative strains (Escherichia coli, Pseudomonas aeruginosa). Despite the presence of copper, MG-63 osteoblast-like cells demonstrated sustained viability and successful extracellular matrix mineralisation, indicating excellent cytocompatibility of the coatings with bone-forming cells. These results demonstrate that multilayer Ti–Cu oxide coatings can effectively balance antibacterial performance, corrosion resistance, mechanical strength, and support bone cell integration, making them a promising strategy for the surface modification of titanium-based biomedical implants. Full article

In physiological environments, several metallic alloys, including titanium, stainless steel, cobalt–chromium, and emerging biodegradable systems such as magnesium (Mg), zinc (Zn), and iron (Fe), offer mechanical properties and biocompatibility suitable for load-bearing implants. With the rapid advancement of 3D printing technologies, these alloys can now be fabricated into patient-specific, complex geometries that enhance both structural performance and functional integration. Beyond serving as structural supports, 3D-printed alloys are increasingly engineered as localized drug-delivery platforms to release anti-inflammatory, antibacterial, anticancer, and osteogenic agents at the implant–tissue interface, addressing the dual clinical needs of site-specific therapy and mechanical stabilization. Nevertheless, this field remains underexplored because studies differ widely in alloy chemistry, surface topography, porosity, coating strategy, drug-loading methods, and release profiles, as well as in how material degradation or passivation interacts with pharmacokinetics. For the first time, this review consolidates drug-loading and elution strategies across 3D-printed alloy platforms, compares therapeutic categories in relation to alloy and coating types, and critically evaluates how the surface microstructure or alloy geometry influences release behavior. Full article

Background/Objectives: The purpose of this study was to assess the in vitro biocompatibility and corrosion resistance of five titanium alloys that have been recently developed for dental implant applications, whose compositions were designed to align with current approaches in the development of novel biomaterials. Priority was given to limiting the harmfulness associated with specific chemical elements present in common conventional alloys and increasing corrosion resistance to improve the biomaterial–tissue cellular interaction. Methods: For this purpose, five types of titanium alloys with original chemical compositions (Ti1–Ti5) were developed. The electrochemical behavior of the alloys was analyzed by evaluating the corrosion resistance in environments that simulate the oral environment, as well as the cellular behavior, by evaluating the viability, growth, and proliferation of human cells on osteoblasts and gingival fibroblasts. Detailed analysis of the chemical composition by scanning electron microscope (SEM/EDS) methods was used. The corrosion rate of the alloys in artificial saliva was tested using the polarization resistance technique (Tafel). Human osteoblasts (hFOB cell line) and human gingival fibroblasts (hFIB-G cell line) were used to measure biocompatibility in vitro. Results: The Ti5 alloy demonstrated the highest cell viability and the lowest corrosion rate (0.114 μm/year) among all tested compositions, with the Ti3 alloy containing Mo and Zr following closely behind. The Ti2 alloy exhibited reduced biocompatibility because of the inclusion of Ni and Fe in its composition. Conclusions: Taken together, the results of this study provide useful information on the basic characteristics of titanium alloys with original chemical compositions. The titanium alloys were analyzed in comparison with common conventional alloys (Cp–Ti and Ti6Al4V) as well as alloys such as Ti–Zr, Ti–Nb, and Ti–Nb–Zr–Ta, which are considered to be viable alternatives to conventional materials for making dental implants. Full article

Background: In the treatment of dentofacial deformities, miniplates and screws made of titanium and its alloys (Ti6Al4V) are currently used for osteosynthesis of bone segments, which is due to the high biocompatibility of these materials. Despite the unquestionable advantages of titanium implants, there is an ongoing discussion about their potential negative impact on the human body, both at the implantation site and systemically. This study aimed to assess the influence of titanium fixations (miniplates and screws) on the texture and to identify the texture features that vary in the surrounding bone tissue. Methods: The orthopantomograms were obtained from 20 patients who were treated at the Department of Maxillofacial and Plastic Surgery, University of Bialystok. Regions of Interest (ROIs) of bone tissue surrounding titanium fixations in the maxilla and mandible were annotated using separate masks and compared to healthy areas of the same structures in the same patients. The images were independently filtered using Mean, Median, and Laplacian Sharpening filters, followed by analysis of the texture parameters obtained through methods such as First-Order Statistics (FOS), the Gray-Level Co-occurrence Matrix (GLCM), Neighbouring Gray Tone Difference Matrix (NGTDM), Gray-Level Dependence Matrix (GLDM), Gray-Level Run Length Matrix (GLRLM), and Gray-Level Size Zone Matrix (GLSZM). Results: The results showed that FOS, GLCM, and GLDM provide the most informative features for quantitative assessment of the areas around titanium fixations, and that smoothing filters reduce measurement noise and artifacts. Conclusions: The findings confirm that texture analysis can support the diagnosis of structural alterations in the bone surrounding titanium fixations, in both the maxilla and mandible. Full article

Background/Objectives: The effect of metformin combined with bone grafting materials and its effect on the hydrophilicity of different implant surfaces has not been investigated. Investigation of the use of metformin as a therapeutic for implant surface treatment may be useful in improving overall implant longevity and success. Methods: Herein, a 1.5% metformin solution was created with crystalline metformin and distilled water. Titanium alloy (machined surface), titanium with sandblasted, large-grit acid-etched surface (Ti-SLA), and zirconia (SDS) surfaces were treated with five different solutions: 0.9% sodium chloride (Group A), bovine cancellous bone graft (Bio-Oss^®)/0.9% sodium chloride solution (Group B), Bio-Oss^® bone graft with metformin/0.9% sodium chloride solution (Group C), algae-based bone graft (AlgOss^®)/0.9% sodium chloride solution (Group D), and AlgOss^® bone graft with metformin/0.9% sodium chloride solution (Group E). Hydrophilicity tests utilizing droplet angle measurements (n = 20 droplets/disk) of each of the solutions were carried out (total N = 600 contact angle measurements). Statistical comparison between treatment groups for each implant surface using ANOVA and Bonferroni correction at p < 0.05 was performed. Results: Analyses revealed a statistically significant improvement in hydrophilicity for group C compared to group B (p < 0.05) in Ti-alloy, but a significant decrease in hydrophilicity for group E compared to group D in Ti-SLA. Zirconia surfaces displayed a decrease in hydrophilicity for all groups compared to group A. Conclusions: Thus, there were varying effects of combined metformin and bone graft on implants. Full article

Metallic implants used in orthopedics, such as titanium alloys, possess excellent mechanical strength but suffer from corrosion and poor bio-integration, often necessitating revision surgeries. Bioactive coatings, particularly hydroxyapatite, can enhance implant osteoconductivity, but high-purity synthetic hydroxyapatite is costly. This study investigates the development and characterization of a low-cost, biocompatible coating using hydroxyapatite derived from an unconventional natural source dromedary bone applied onto a titanium substrate via plasma spraying. Hydroxyapatite powder was synthesized from dromedary femurs through a thermal treatment process at 1000 °C. The resulting powder was then deposited onto a sandblasted titanium dioxide substrate using an atmospheric plasma spray technique. The physicochemical, structural, and morphological properties of both the source powder and the final coating were comprehensively analyzed using Scanning Electron Microscopy, Energy Dispersive X-ray Spectroscopy, X-ray Diffraction, and Fourier-Transform Infrared Spectroscopy. Characterization of the powder confirmed the successful synthesis of pure, crystalline hydroxyapatite, with Fourier-Transform Infrared Spectroscopy analysis verifying the complete removal of organic matter. The plasma-sprayed coating exhibited good adhesion and a homogenous, lamellar microstructure typical of thermal spray processes, with an average thickness of approximately 95 μm. X-ray Diffraction analysis of the coating revealed that while hydroxyapatite remained the primary phase, partial decomposition occurred during spraying, leading to the formation of secondary phases, including tricalcium phosphate and calcium oxide. Scanning Electron Microscopy imaging showed a porous surface composed of fully and partially melted particles, a feature potentially beneficial for bone integration. The findings demonstrate that dromedary bone is a viable and low-cost precursor for producing bioactive hydroxyapatite coatings for orthopedic implants. The plasma spray method successfully creates a well-adhered, porous coating, though process-induced phase changes must be considered for biomedical applications. Full article

Titanium alloys are widely employed for biomedical implants due to their high strength, biocompatibility, and corrosion resistance, yet their lack of intrinsic antibacterial activity remains a major limitation. Incorporating copper, an antibacterial and β-stabilising element, offers a promising strategy to enhance implant performance. This study investigates Ti-6Al-7Nb modified with 1–9 wt.% Cu via in situ alloying during metal-based laser powder bed fusion (PBF-LB/M), with the aim of assessing processability, microstructural evolution, and mechanical properties. Highly dense samples (>99.9%) were produced across all Cu levels, though chemical homogeneity strongly depended on processing parameters. Increasing Cu content promoted β-phase stabilisation, Ti₂Cu precipitation, and pronounced grain refinement. Hardness and yield strength increased nearly linearly with Cu addition, while ductility decreased sharply at ≥5 wt.% Cu due to intermetallic formation, hot cracking, and brittle fracture. These results illustrate both the opportunities and constraints of rapid alloy screening via PBF-LB/M. Overall, moderate Cu additions of 1–3 wt.% provide the most favourable balance between mechanical performance, manufacturability, and potential antibacterial functionality. These findings provide a clear guideline for the design of Cu-functionalised titanium implants and demonstrate the efficiency of in situ alloy screening for accelerated materials development. Full article

Postoperative infections in orthopedic implants remain a major complication, particularly in open fractures, where early bacterial colonization and the limited bioactivity of titanium alloys hinder osseointegration. This study reports a hierarchical coating synthesized in situ on Ti-407 alloy, integrating bioactive and antibacterial functions. TiO₂ nanotube arrays were formed by anodization and subsequently functionalized by sequential electrodeposition of Ag nanoparticles and doped hydroxyapatite (HA) (Ca, P, Mg, Zn). SEM/EDS confirmed uniform coatings with a Ca/P ratio near stoichiometric HA (1.61). Agar diffusion assays against E. coli ATCC® 25922™ revealed well-defined inhibition zones, confirming the antibacterial efficacy of the coatings. These findings highlight the potential of hierarchical coatings to enhance bone integration while reducing infection risk in orthopedic implants. Full article

The surface modification of medical implant materials stands as a favorable strategy to enhance their biological properties including their antibacterial effect and biocompatibility. Recently, both in vitro and in vivo studies have shown that film heterostructures based on a combination of noble metal sublayers and an active component, such as silver and gold nanoparticles, offer unique advantages. The present work develops this promising direction and focuses on a series of combinations of noble metal coatings functionalized with bimetallic nanoclusters obtained by vapor-phase deposition methods onto the surfaces of Ti-based implants. This investigation investigates the influence of sequential deposition (AgAu or AuAg) and noble metal component (Ir or Au) on the coating morphology and the active component chemical form and release. Thus, scanning electron microscopy, X-ray photoelectron spectroscopy, and inductively coupled plasma atomic emission spectroscopy have been applied to characterize the samples before and after in vivo biological studies (rat models, 1 and 3 months). Histological and blood analyses confirmed the high biocompatibility of all the heterostructures. The samples also showed a pronounced in vitro biocidal effect against Gram-positive (S. epidermalis) and Gram-negative (P. aeruginosa) bacteria that correlates with a dynamic of silver release. The AuAg/M heterostructures demonstrated superior biological characteristics compared to their AgAu/M counterparts, suggesting enhanced both long-term integration and antibacterial action. Full article

Titanium (Ti) and its alloys are widely used in orthopedic applications, including total hip and knee replacements, bone plates, and dental implants, because of their superior biocompatibility, bioactivity, corrosion resistance, and mechanical robustness. These alloys effectively overcome several limitations of conventional metallic implants, such as 316L stainless steel and Co-Cr alloys, particularly with respect to corrosion, fatigue performance, and biological response. However, dense Ti alloys possess a relatively high elastic modulus, which can cause stress shielding in load-bearing applications. This challenge has motivated significant research toward engineered porous Ti structures that exhibit a reduced and bone-matched modulus while preserving adequate mechanical integrity. This review provides a comprehensive examination of powder metallurgy and additive manufacturing approaches used to fabricate porous Ti and Ti-alloy scaffolds, including additive manufacturing and different powder metallurgy techniques. Processing routes are compared in terms of achievable porosity, pore size distribution, microstructural evolution, mechanical properties, and biological outcomes, with emphasis on the relationship between processing parameters, pore architecture, and functional performance. The reported findings indicate that optimized powder-metallurgy techniques can generate interconnected pores in the 100–500 μm range suitable for osseointegration while maintaining compressive strengths of 50–300 MPa, whereas additive manufacturing enables the precise control of hierarchical architectures but requires careful post-processing to remove adhered powder, stabilize microstructures, and ensure corrosion and wear resistance. In addition, this review integrates fundamental aspects of bone biology and bone implant interaction to contextualize the functional requirements of porous Ti scaffolds. Full article

In this work, two configurations of Ti/HAp functionally graded coatings were fabricated on Ti–6Al–4V alloy substrates using detonation spraying. The coatings differed in the number and sequence of Ti and hydroxyapatite (HAp) deposition cycles, resulting in distinct gradient architectures: Configuration 1 incorporated a sharper transition from the Ti-rich base to the HAp-rich surface, whereas Configuration 2 featured a smoother and more gradual compositional gradient. The microstructure and elemental distribution were examined by scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS). Both configurations exhibited well-defined gradient layering, with titanium concentrated near the coating–substrate interface and an increased Ca and P content toward the upper bioceramic region. Raman spectroscopy confirmed the preservation of hydroxyapatite as the main phase, showing a characteristic 961 cm⁻¹ band. Adhesion strength measured according to ASTM C633-13 was 45.78 ± 4.4 MPa for Configuration 1 and 52.32 ± 6.7 MPa for Configuration 2, both significantly exceeding the minimum required 15 MPa. The findings demonstrate that detonation-sprayed Ti/HAp gradient coatings provide strong adhesion and stable bioceramic surfaces, making them promising for metal implant applications. Full article

The growing demand for reliable orthopedic implants has driven extensive research into biomaterials and metal alloys for the development of bone scaffolds. This review summarizes current progress in improving scaffold performance by optimizing mechanical strength, biocompatibility, and bone integration. Key studies on material choice, modeling methods, manufacturing techniques, and surface treatments are discussed, with a special focus on titanium-based alloys due to their favorable mechanical and biological properties. Computational tools, particularly finite element modeling, are increasingly used alongside experimental findings to illustrate mechanical behavior and to guide design of structures that more closely resemble natural bone. Both additive and traditional manufacturing routes are considered, emphasizing how porosity, geometry, and fabrication parameters affect mechanical stability and tissue response. Surface modification approaches, both physical and chemical can enhance cell attachment and antimicrobial function. Overall, this paper shows how combining materials science, mechanical analysis, and biological testing helps develop bone scaffolds that offer durable mechanical support and clinical outcomes. Full article

This work describes the preparation and characterization of chitosan-based biopolymer coatings containing silver, zinc, and hydroxyapatite nanoparticles deposited on the Ti13Zr13Nb alloy by the EPD method. It was intended to evaluate the influence of surface pretreatments and deposition parameters on the structural, electrochemical, and biological properties of coatings. The morphology and composition were characterized by means of SEM/EDS, AFM, XRD, and FTIR analysis. The obtained results indicated uniform continuous layers with homogeneously distributed nanoparticles and the presence of characteristic functional groups originating from chitosan and hydroxyapatite. Corrosion investigations performed in SBF solution revealed a significant enhancement in corrosion resistance for chitosan/nanoAg/nanoZn/nanoHAp coatings, reflected in a drastic decrease in corrosion current density compared with uncoated Ti13Zr13Nb alloy. The contact angle measurements confirmed their hydrophilic nature, which favors better biointegration ability. Biological tests (MTT and LDH) performed on human osteoblasts (hFOB 1.19) confirmed high biocompatibility (>85% cell viability) in the case of all coatings with the addition of hydroxyapatite, whereas in the case of coatings without HAp, cytotoxicity was observed, probably due to the uncontrolled release of metallic nanoparticles. These findings suggest that the presence of hydroxyapatite in chitosan-based coatings efficiently enhances corrosion protection and cytocompatibility, showing very good prospects for biomedical applications such as the surface modification of titanium implants. Full article