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Hybrid additive manufacturing for Zn-Mg casting for biomedical application.

Kazi Safowan Shahed1, Matthew Fainor2,3, Sarah E Gullbrand2,3

  • 1Department of Industrial and Manufacturing Engineering, Pennsylvania State University, State College, University Park, PA USA.

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|January 29, 2025
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Summary

Researchers developed a novel hybrid manufacturing process for biodegradable orthopaedic implants using zinc-magnesium alloys with gyroid structures. This method shows promise for creating advanced implants with excellent biocompatibility and mechanical properties.

Keywords:
Additive manufacturingIn vitro tissue engineeringIntermetallicsInvestment castingMechanical propertiesTissue engineering

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Area of Science:

  • Biomaterials Engineering
  • Orthopaedic Implant Technology
  • Additive Manufacturing

Background:

  • Zinc (Zn) and its alloys are investigated for orthopaedic implants due to mechanical strength, biodegradability, and biocompatibility.
  • Additive Manufacturing (AM) offers advanced fabrication possibilities for complex implant geometries.

Purpose of the Study:

  • To develop a novel hybrid manufacturing process for zinc-magnesium (Zn-0.8Mg) orthopaedic implants.
  • To fabricate Zn-0.8Mg artifacts with gyroid surface lattices using AM-augmented casting.
  • To evaluate the material properties and biocompatibility of the fabricated implants.

Main Methods:

  • Utilized additive manufacturing (AM) augmented casting to fabricate Zn-0.8Mg artifacts.
  • Characterized material composition and microstructure using Scanning Electron Microscopy (SEM) and Energy-Dispersive X-ray Spectroscopy (EDS).
  • Assessed mechanical properties through micro indentation testing (hardness and elastic modulus).
  • Evaluated biocompatibility via in vitro cell culture experiments.

Main Results:

  • Successfully fabricated Zn-Mg artifacts with gyroid surface lattices.
  • Identified Zn-Mg intermetallic phases at the grain boundary via SEM/EDS.
  • Measured hardness values between 83.772-99.112 HV and elastic modulus of 92.601-94.625 GPa.
  • Demonstrated robust cell survival on both gyroid and solid scaffolds in vitro.

Conclusions:

  • The novel hybrid manufacturing process is a viable approach for next-generation biodegradable orthopaedic implants.
  • Zn-0.8Mg alloy with gyroid structures exhibits suitable mechanical properties and biocompatibility for biomedical applications.
  • This fabrication technique holds potential for advancing orthopaedic implant design and functionality.