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Fused Filament Fabrication (FFF) is a widespread additive manufacturing technology, mostly in the field of printable polymers. The use of filaments filled with metal particles for the manufacture of metallic parts by FFF presents specific challenges regarding debinding and sintering. For aluminium and its alloys, the sintering temperature range overlaps with the temperature range of thermal decomposition of many commonly used “backbone” polymers, which provide stability to the green parts. Moreover, the high oxygen affinity of aluminium necessitates the use of special sintering regimes and alloying strategies. Therefore, it is challenging to achieve both low porosity and low levels of oxygen and carbon impurities at the same time. Feedstocks compatible with the special requirements of aluminium alloys were developed. We present results on the investigation of debinding/sintering regimes by Fourier Transform Infrared spectroscopy (FTIR) based In-Situ Process Gas Analysis and discuss optimized thermal treatment strategies for Al-based FFF.
Inadequate mechanical compliance of orthopedic implants can result in excessive strain of the bone interface, and ultimately, aseptic loosening. It is hypothesized that a fiber-based biometal with adjustable anisotropic mechanical properties can reduce interface strain, facilitate continuous remodeling, and improve implant survival under complex loads. The biometal is based on strategically layered sintered titanium fibers. Six different topologies are manufactured. Specimens are tested under compression in three orthogonal axes under 3-point bending and torsion until failure. Biocompatibility testing involves murine osteoblasts. Osseointegration is investigated by micro-computed tomography and histomorphometry after implantation in a metaphyseal trepanation model in sheep. The material demonstrates compressive yield strengths of up to 50 MPa and anisotropy correlating closely with fiber layout. Samples with 75% porosity are both stronger and stiffer than those with 85% porosity. The highest bending modulus is found in samples with parallel fiber orientation, while the highest shear modulus is found in cross-ply layouts. Cell metabolism and morphology indicate uncompromised biocompatibility. Implants demonstrate robust circumferential osseointegration in vivo after 8 weeks. The biometal introduced in this study demonstrates anisotropic mechanical properties similar to bone, and excellent osteoconductivity and feasibility as an orthopedic implant material.
Biodegradable metals have entered the implant market in recent years, but still do not show fully satisfactory degradation behaviour and mechanical properties. In contrast, it has been shown that pure molybdenum has an excellent combination of the required properties in this respect. We report on PM based screen printing of thin-walled molybdenum tubes as a processing step for medical stent manufacture. We also present data on the in vivo degradation and biocompatibility of molybdenum. The degradation of molybdenum wires implanted in the aorta of rats was evaluated by SEM and EDX. Biocompatibility was assessed by histological investigation of organs and analysis of molybdenum levels in tissue extracts and body fluids. Degradation rates of up to 13.5 μm/y were observed after 12 months. No histological changes or elevated molybdenum levels in organ tissues were observed. In summary, the results further underline that molybdenum is a highly promising biodegradable metallic material.