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Optimization Scheme for 3D Printing of PLA-PHBV-PCL Biodegradable Blends for Use in Orthopedic Casting
Muhammad Mohid Aziz1, Logan Beard1, Shafahat Ali1
1Advanced Manufacturing Lab (AML), School of Engineering, University of Guelph, Guelph, ON N1G 2W1, Canada.
Polymers
|April 12, 2025
Summary
This study optimized 3D printed orthopedic casts using a blend of polylactic acid (PLA) with PHBV and PCL. Optimal printing parameters significantly improved mechanical properties for enhanced cast performance.
Area of Science:
- Materials Science
- Biomedical Engineering
- Additive Manufacturing
Background:
- Three-dimensional (3D) printing offers advantages for orthopedic cast production over traditional materials.
- Polylactic acid (PLA) is a common 3D printing material but has limitations like brittleness and low thermal stability.
- Blending PLA with poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) and polycaprolactone (PCL) can enhance its properties for orthopedic applications.
Purpose of the Study:
- To investigate the mechanical properties of a 3D printable PLA/PHBV/PCL blend for orthopedic casts.
- To optimize 3D printing parameters (nozzle temperature, layer height, raster angle) for improved mechanical performance.
- To apply Grey Relational Analysis (GRA) for optimizing the blend's mechanical characteristics.
Main Methods:
- Developed a 3D printable blend of polylactic acid (PLA), poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), and polycaprolactone (PCL).
- Evaluated key mechanical properties: tensile strength, elongation at break, Young's modulus, flexural strength, flexural modulus, and impact strength.
- Utilized Grey Relational Analysis (GRA) to determine optimal printing parameters and Analysis of Variance (ANOVA) for statistical significance.
Main Results:
- Optimal printing parameters identified as 180 °C nozzle temperature, 0.18 mm layer height, and 0° raster angle.
- Achieved enhanced mechanical properties: 44.4 MPa tensile strength, 68.5% elongation at break, 948.7 MPa Young's modulus, 54.6 MPa flexural strength, 1549.3 MPa flexural modulus, and 80.77 J/m impact strength.
- Raster angle significantly influenced tensile, flexural, and impact strength, followed by layer height and nozzle temperature.
Conclusions:
- The optimized PLA/PHBV/PCL blend and printing parameters significantly enhance mechanical properties for 3D printed orthopedic casts.
- The study demonstrates a viable approach to overcoming PLA's limitations for advanced orthopedic applications.
- The findings provide a foundation for developing improved, customized orthopedic cast solutions using additive manufacturing.
