Design and fabrication of cast orthopedic implants with freeform surface textures from 3-D printed ceramic shell

Journal of Biomedical Materials ResearchVolume 53, Issue 5 p. 525-535 Research Article Design and fabrication of cast orthopedic implants with freeform surface textures from 3-D printed ceramic shell Alain Curodeau, Corresponding Author Alain Curodeau [email protected] Département de génie mécanique, Université Laval, Sainte–Foy, QC, CanadaUniversité Laval, Mechanical Engineering Department, Sainte-Foy, QC G1K 7P4, CanadaSearch for more papers by this authorEmanuel Sachs, Emanuel Sachs Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, MASearch for more papers by this authorSalvatore Caldarise, Salvatore Caldarise Applied Research Laboratory, Johnson & Johnson Professional Inc., Raynham, MASearch for more papers by this author Alain Curodeau, Corresponding Author Alain Curodeau [email protected] Département de génie mécanique, Université Laval, Sainte–Foy, QC, CanadaUniversité Laval, Mechanical Engineering Department, Sainte-Foy, QC G1K 7P4, CanadaSearch for more papers by this authorEmanuel Sachs, Emanuel Sachs Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, MASearch for more papers by this authorSalvatore Caldarise, Salvatore Caldarise Applied Research Laboratory, Johnson & Johnson Professional Inc., Raynham, MASearch for more papers by this author First published: 31 July 2002 https://doi.org/10.1002/1097-4636(200009)53:5<525::AID-JBM12>3.0.CO;2-1Citations: 121AboutPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShare Give accessShare full text accessShare full-text accessPlease review our Terms and Conditions of Use and check box below to share full-text version of article.I have read and accept the Wiley Online Library Terms and Conditions of UseShareable LinkUse the link below to share a full-text version of this article with your friends and colleagues. Learn more.Copy URL Share a linkShare onEmailFacebookTwitterLinkedInRedditWechat Abstract Three-dimensional printing is a solid freeform fabrication process, which creates parts directly from a computer model. The parts are built by repetitively spreading a layer of powder and selectively joining the powder in the layer by ink-jet printing of a binder material. 3D printing was applied to the fabrication of sub-millimeter surface textures with overhang and undercut geometries for use in orthopedic prostheses as bony ingrowth structures. 3D printing is used to fabricate ceramic molds of alumina powder and silica binder, and these molds are used to cast the bony ingrowth surfaces of Co-Cr (ASTM F75) alloy. Minimum positive feature sizes of the ceramic mold and, therefore, minimum negative feature sizes of castings were determined to be approximately 200 × 200 × 175 μm and were limited by the strength of ceramic needed to withstand handling. Minimum negative feature sizes in the ceramic mold and, therefore, minimum positive features in the casting were found to be approximately 350 × 350 × 175 μm and were determined by limitations on removal of powder from the ceramic and the pressure required to fill these small features with molten metal during casting. Textures were designed with 5 layers of distinct geometric definition, allowing for the design of overhung geometry with overall porosity ranging from 30–70%. Features as small as 350 × 350 × 200 μm were included in these designs and successfully cast. © 2000 John Wiley & Sons, Inc. J Biomed Mater Res (Appl Biomater) 53: 525–535, 2000 REFERENCES 1 Bobyn JD, Pilliar RM, Cameron HU, Weatherly GC. The optimum pore size for the fixation of porous-surfaced metal implants by the ingrowth of bone. Clin Ortho Rel Res 1980; 150: 263. 2 Spector Myron. Historical review of porous-coated implants. 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