Manufacturing-induced geometric deviations and corrosion-driven morphological evolution in magnesium lattice...

Area of Science:

• Materials Science
• Biomaterials Engineering
• Additive Manufacturing

Background:

• Lattice scaffolds are crucial in biomedical applications, but their structural integrity is challenged by manufacturing variability and degradation.
• Understanding geometric evolution during fabrication and corrosion is vital for predicting scaffold performance.

Purpose of the Study:

• To quantify strut-level geometric changes in AZ31 alloy lattice scaffolds throughout manufacturing and corrosion.
• To establish the relationship between fabrication-induced deviations and long-term morphological stability.

Main Methods:

• Utilized Digital Light Processing (DLP) printing for resin templates and vacuum-assisted casting with NaCl molds for AZ31 alloy scaffolds.
• Employed a micro-computed tomography (micro-CT) framework with voxel-wise thickness mapping and 3D deviation analysis.
• Quantified geometric evolution during fabrication (resin to as-cast) and simulated physiological corrosion (DMEM).

Main Results:

• Resin templates showed ~4% shrinkage; as-cast scaffolds exhibited an 8.8% size increase due to material redistribution, with deviations up to ±100 μm.
• Fabrication introduced significant geometric deviations, particularly at nodes and unsupported strut segments.
• Corrosion led to progressive strut thinning and Mg2+ release, but preserved the global lattice architecture.

Conclusions:

• Manufacturing-induced geometric deviations are a primary determinant of lattice scaffold structural fidelity.
• The developed micro-CT workflow effectively tracks structural evolution across fabrication and degradation.
• Fabrication variability sets the stage for predictable, time-dependent morphological changes during scaffold use.