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Producing hip implants of titanium alloys by additive manufacturing

Article · June 2016

DOI: 10.18063/IJB.2016.02.004

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RESEARCH ARTICLE

Producing hip implants of titanium alloys by additive

manufacturing
Anatoliy Popovich, Vadim Sufiiarov, Igor Polozov*, Evgenii Borisov and Dmitriy Masaylo
Peter the Great St. Petersburg Polytechnic University, Politekhnicheskaya ul., 29, St Petersburg, Russia, 195251

Abstract: Additive manufacturing (AM) technologies, in particular Selective Laser Melting (SLM) allows the produc-
tion of complex-shaped individual implants from titanium alloys with high biocompatibility, mechanical properties, and
improved osseointegration by surface texturing. In this work, the possibility of producing a custom-made hip implant
from Ti-6Al-4V powder according to the data acquired via computed tomography of the patient is shown. Different heat
treatments were applied in order to achieve better combination of tensile strength and elongation by partial decomposi-
tion of the martensitic phase. The implant was installed to the patient, postoperative supervision has shown good results,
and the patient is able to move with the installed implant. A successful case of applying AM for producing custom hip
implant is demonstrated in the paper. Using AM allowed the production of a custom-made hip implant in a short time
and decreases the operation time and lessens the risk of infection ingress.
Keywords: selective laser melting, implant, Ti-6Al-4V, biomedical application, prosthesis

*Correspondence to: Igor Polozov, Peter the Great St. Petersburg Polytechnic University, Politekhnicheskaya ul., 29, St Petersburg, Russia,
195251; Email: [email protected]

Received: April 11, 2016; Accepted: May 17, 2016; Published Online: June 28, 2016
Citation: Popovich A, Sufiiarov V, Polozov I, et al., 2016, Producing hip implants of titanium alloys by additive manufacturing.
International Journal of Bioprinting, vol.2(2): 78–84. http://dx.doi.org/10.18063/IJB.2016.02.004.

1. Introduction SLM consists of forming powder layers, melting them

via laser irradiation, and fusing with the previous layer

A
dditive manufacturing (AM) technologies, according to the CAD-data. Owing to the fully melted
also known as 3D printing, have demonstrat- powder particles, the produced parts have a high rela-
ed a tremendous growth for the past 30 years tive density close to 100% and high cooling rates[6−8]
from the development of the first polymer machines to induce fine-dispersed microstructures typical for this
the manufacturing of functional metal parts with ad- method and high mechanical properties[9−11].
vanced characteristics and bioprinting[1−3]. AM com- Endoprosthesis replacement is one of the most suc-
bines the use of digital design to create a 3D-model of cessful techniques for surgical treatment of patients
the part and produce the part by adding layers of ma- with injuries and hip joint diseases. The demand for
terials using different techniques. AM allows the pro- endoprosthesis replacement is increasing globally[12].
duction of not only prototypes, but fully functional According to the Hip Arthroplasty Register, about
components for aerospace, the automobile industry, 40,000 arthroplastic surgeries are performed annually
medicine, and et cetera[4,5]. Given the layer-by-layer in the northern European countries; at the same time
manufacturing manner, complex-shaped parts can be more than a million surgeries are performed around
made without using additional tools and joints. Selec- the world and it is expected to double in the near 20
tive Laser Melting (SLM) is one of the most promis- years[13]. Despite the high efficiency of endoprosthesis
ing and used methods among metal AM techniques. replacement, a high percent of patients require a revi-

Producing hip implants of titanium alloys by additive manufacturing. © 2016 Anatoliy Popovich, et al. This is an Open Access article distributed
under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/),
permitting all non-commercial use, distribution, and reproduction in any medium, provided the original work is properly cited.
78
 Anatoliy Popovich, Vadim Sufiiarov, Igor Polozov, et al.

sion surgery 10–15 years after the first implantation. Selective Laser Sintering (SLS) from polyamide po-
Aseptic instability and paraprosthetic osteolysis are wder using a 3D Systems Sinterstation HiQ+HS ma-
considered to be the main reasons for the loosening of chine. After making a polyamide model of the pa-
implants[14]. tient’s bone, the design of the implant configuration
The most frequent method of an unsteady implant was carried out using CAD-software. Owing to severe
replacement is the installation of acetabular compo- deformations of the hip bone, the physical model of
nents with press-fit fixation in the presence of un- the implant was made out of polymer clay, taking into
harmed support bones[15−17]. Three-flank acetabular account anatomical features of the patient. The im-
systems are modeled based on computed tomography plant was 3D-scanned using a Faro Platinum Arm
(CT) data of the patient, designing a 3D-model of pa- scanner to obtain a CAD-file of the implant. The con-
tient’s hip bones considering bone defects, and allow- figuration of the implant was further improved using
ing angles of dimensional orientation of the acetabular CAD-software; in particular, a partial texturing of the
component. implant surface has been done.
Titanium alloys—Ti-6Al-4V in particular—are wi- Ti-6Al-4V Grade 5 powder was used as the initial
dely used in different industries. One of the applica- material for manufacturing the metal implant, pro-
tion of Ti-6Al-4V alloys is the manufacturing of med- duced by plasma atomization. The particles have a
ical implants due to its high biocompatibility and a spherical form without any defects in the form of sa-
combination of mechanical properties[18−20]. Since SLM tellites (Figure 1) with the following particle size dis-
technology allows the manufacturing of near net- tribution: d10 = 27 µm; d50 = 47 µm; d90 = 76 µm. The
shape parts with complex geometry, it is possible to metal implant was manufactured using SLM Solutions
make custom-made implants for each specific patient SLM 280HL machine with the parameters set provid-
while also texturing the implant’s surface with a lattice
ing the relative density of about 99.9% and described
structure for better osseointegration[21,22]. There have
in other works[26,27]. The build accuracy of the manu-
been several attempts to manufacture implants via
factured implant is about 200 µm. A schematic se-
SLM technology from titanium alloys using Ti-6Al-4V,
quence of operations used to produce a titanium hip
CoCr alloys[23, 24], as well as using Ti-Ta alloy powder,
which is promising for medical applications[25]. Ano- implant by AM is presented in Figure 2.
ther metal additive manufacturing technique for pro- Microstructure studies were performed using a Le-
ducing complex parts from titanium alloy powders is ica DMI 5000 light microscope. Mechanical tests were
Electron Beam Melting (EBM), which uses electron carried out on Zwick/Roell – Z100 machine using sta-
beam energy for melting metal powder layer-by-layer ndard samples manufactured by SLM and then mac-
in vacuum[23]; a promising technology for manufac- hined to the specific size according to ASTM E8/E8M.
turing individual implants from titanium alloys. Usu- Three specimens were used for each test point. An-
ally, patient’s anatomical data is reconstructed in 3D nealing was carried out using a vacuum furnace, ALD
and used for geometric modelling of implants. MonoTherm in a vacuum with a pressure of 10−3–10−4
In this paper, we demonstrate the possibility of mbar.
producing individual acetabular revision systems to
carry out a revised endoprosthesis replacement of a
hip implant made of Ti-6Al-4V alloy by using AM
and data of the patient’s bone configuration acquired
by CT. CT-data is used for 3D printing a polymer
model of the patient’s deformed bone, creating a pro-
totype of the implant for modeling the surgery process.
The final model of the part is used for manufacturing
the hip implant from Ti-6Al-4V alloy powder by SLM.

2. Materials and Methods

(A) (B)
CT-data of the patient’s hip bone structure in DICOM Figure 1. SEM images of Ti-6Al-4V powder particles, pro-
file-format was used to make a physical model of the duced by plasma atomization with (A) X200 and (B) X1000
patient’s hip bone, which was then manufactured via magnification.

International Journal of Bioprinting (2016)–Volume 2, Issue 2 79

Producing hip implants of titanium alloys by additive manufacturing

Figure 2. Sequence of operations used to produce an implant via additive manufacturing.

In order to take into account severe deformations of

3. Results and Discussion the hip bone, a physical model of the acetabular hip
Using CT-data of the patient’s bone structure, a 3D- implant was made out of polymer clay, which consid-
model of the hip bone was formed by matching the ers the deformations and future points of bearing. Af-
size and form of the patient’s bone. The polyamide ter that, the polymer implant model was 3D-scanned
model of the hip bone was then 3D-printed using a and the implant configuration was further designed
SLS machine (Figure 3). The build accuracy of the considering the implant’s rotation center. Using the
SLS model is around 100 µm. CAD-model of the implant, its surface was partially
texturized to increase its roughness and create areas
with high specific surface in order to increase contact
surface with the human bone and improve osseointe-
gration[28]. The obtained CAD-model was used to pro-
duce a polyamide implant model, simulating endo-
prosthesis replacement with the made models.
The CAD-model of the implant was positioned rel-
ative to the building plate of the SLM machine using
Materialise Magics software—support structures were
also created to preserve the implant geometry during
the building process. The implant orientation was
chosen in such a way as to minimize thermal stresses
during SLM and minimize a number of supports.
Supports were placed on the surfaces that do not have
special patterns in order to simplify the removal pro-
cess and prevent residuals of the supports from rem-
Figure 3. The polyamide model of the patient’s hip bone. aining on the implant’s surface. The chosen orientation
80 International Journal of Bioprinting (2016)–Volume 2, Issue 2
 Anatoliy Popovich, Vadim Sufiiarov, Igor Polozov, et al.

of the implant is shown in Figure 4A, while the other cooling. The microstructures of the bulk material after
possible orientation is demonstrated in Figure 4B. SLM and after the second type of heat treatment are
Then the acetabular custom-made implant was pro- shown in Figure 6. Before annealing, the microstruc-
duced by SLM out of Ti-6Al-4V powder (Figure 5). ture consists of α′-phase (Figures 6A and B), which is
The build accuracy of the manufactured titanium im- the result of high cooling rates during the SLM pro-
plant is around 200 µm. After heat treatment, the sup- cess[29] and similar to the microstructures in litera-
ports were removed from the implant, it was shot ture[30,31]. Metastable martensitic α′-phase and the α-ph-
peened, additionally cleaned, and prepared by medical ase have HCP crystalline structure. The main differ-
staff—the implant was then installed into the patient ence between them is the greater amount of vanadium
during surgery. Postoperative supervision has shown in the martensitic phase compared to the α-phase[6].
good results; the patient can move with the installed The material after SLM shows high tensile strength,
implant. but low elongation at break (Table 1). High tempera-
Two types of heat treatment were applied to the Ti- ture gradients during SLM result in increased thermal
6Al-4V material after SLM. Annealing was carried out stresses in the material[29] and high residual stresses in
in vacuum with the following parameters: 1) 950 °С the produced part[32,33]; wherefore annealing is needed
for 1.5 hours; 2) 800 °С for 4 hours; both with furnace for achieving better mechanical properties and stress

(A) (B)
Figure 4. Possible variations of the implant orientation on the build platform: (A) supports are placed on the surfaces without textur-
ing, this one was chosen for manufacturing the implant by SLM, (B) supports are placed on the texture surfaces of the implant.

(A) (B)
Figure 5. The Ti-6Al-4V hip implant produced by SLM: (A) general view with supports; (B) a closer view of the texturized surface.

International Journal of Bioprinting (2016)–Volume 2, Issue 2 81

Producing hip implants of titanium alloys by additive manufacturing

(A) (B)

(C) (D)
Figure 6. Microstructures of the Ti-6Al-4V alloy produced by SLM before (A, B) and after annealing at 800°С (C, D): α-phase (gray
lamellae), β-phase (black lines).

relieving. After annealing (Figures 6C and D), a par- Powder Bed Fusion) and ISO 5832-3 (Implants for
tial decomposition of the α ′-phase into the α- and β-ph- surgery – Metallic materials – Part 3: Wrought titanium
ases occurred with enlargement of the acicular α′- 6-aluminium 4-vanadium alloy).
phase and formation of the β-phase on grain bounda-
ries and needles of the martensitic phase. Heat treat- 4. Conclusion
ment of the produced material leads to increased elon- The capabilities of additive manufacturing technolo-
gation at break with a slight decrease in tensile stre- gies were shown to successfully produce a custom-
ngth. Different annealing parameters used in this work made component of a hip implant endoprosthesis from
did not noticeably affect the mechanical properties of Ti-6Al-4V alloy.
the material. Compared to the properties of the Ti- Since the configuration of the implant matches the
6Al-4V alloy obtained by EBM, SLM materials shows anatomical features of the patient, the risk of early
higher tensile strength, but significantly lower elonga- instability development is decreased, the surgery time
tion at break. This might be due to higher cooling rates is reduced together with blood loss and risk of infectious
during the SLM process which result in finer micro- complication development. The possibility of creating
structures and higher residual stresses of the SLM- a texturized surface of the implant by SLM technology
material. The overall mechanical properties (Table 1) allows to potentially improve the osseointegration
of the produced material meet the requirements of process by creating areas with high specific surface.
ASTM F2924–14 (Standard Specification for Additive Microstructures of the produced material after an-
Manufacturing Titanium-6 Aluminum-4 Vanadium with nealing consist of partially decomposed martensitic
82 International Journal of Bioprinting (2016)–Volume 2, Issue 2
 Anatoliy Popovich, Vadim Sufiiarov, Igor Polozov, et al.

Table 1. Mechanical properties of Ti-6Al-4V after SLM and uring of medical parts. Rapid Prototyping Journal,
heat treatment vol.13(4): 196–203.
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Conflict of Interest and Funding 718 produced by SLM and subsequent heat treatment.
Key Engineering Materials, vol.651–653: 665–670.
The authors declare no conflict of interest. http://dx.doi.org/10.4028/www.scientific.net/KEM.651-
653.665
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