Online from: 1995
Subject Area: Mechanical & Materials Engineering
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|Title:||Selective laser melted prototype of original minimally invasive resurfacing hip endoprosthesis|
|Author(s):||Ryszard Uklejewski, (Department of Medical Bioengineering Fundamentals, Institute of Technology, Kazimierz Wielki University, Bydgoszcz, Poland and Medical Bioengineering Group, Department of Process Engineering, Institute of Chemical Technology & Engineering, Poznan University of Technology, Poznan, Poland), Mariusz Winiecki, (Department of Medical Bioengineering Fundamentals, Institute of Technology, Kazimierz Wielki University, Bydgoszcz, Poland), Piotr Rogala, (Department of Spine Surgery, Oncologic Orthopaedics and Traumatology, Karol Marcinkowski University of Medical Sciences in Poznan, Poznan, Poland and Department of Medical Bioengineering Fundamentals, Institute of Technology, Kazimierz Wielki University, Bydgoszcz, Poland), Janusz Mielniczuk, (Poznan University of Technology, Poznan, Poland)|
|Citation:||Ryszard Uklejewski, Mariusz Winiecki, Piotr Rogala, Janusz Mielniczuk, (2011) "Selective laser melted prototype of original minimally invasive resurfacing hip endoprosthesis", Rapid Prototyping Journal, Vol. 17 Iss: 1, pp.76 - 85|
|Keywords:||Advanced manufacturing technologies (SLM), Orthopaedics, Resurfacing hip arthroplasty endoprosthesis|
|Article type:||Case study|
|DOI:||10.1108/13552541111098653 (Permanent URL)|
|Publisher:||Emerald Group Publishing Limited|
|Acknowledgements:||This research was supported by the Polish Ministry of Science, research project no. 4T07C05629: “Experimental investigation and design of the constructional properties of bone-porous implants fixations” (head. R. Uklejewski). The authors thank Dr M. Ambroziak (WADIM Plast Narojek Co., Poland), Mr S. Ritt and Dr D. Schwarze (MTT Technologies Group, Germany) for their kindness during the subcontracted manufacturing of SLM prototypes in SLM technology.|
Purpose – The aim of this paper is to present the main results of a research project finished in 2008 which concerned the selective laser melted (SLM) prototype of a new kind of minimally invasive resurfacing hip arthroplasty (RHA) endoprosthesis with the original multi-spiked connecting scaffold (MSC-Scaffold). Previous attempts performed in pre-Direct Metal Manufacturing (DMM) era demonstrated that it was impossible to manufacture suitable prototypes of this RHA endoprosthesis (especially of the MSC-Scaffold) using traditional machining technologies. Owing to an extensive development of DMM technologies observed in recent years the manufacturing of such prototypes has become possible.
Design/methodology/approach – Computer aided design models of pre-prototypes and the prototype of the RHA endoprosthesis with MSC-Scaffold were designed and initially optimized within the claims and the general assumptions of international patents by Rogala. Prototyping in SLM technology was subcontracted to SLM Tech Center (Paderborn, Germany). Macroscopic and SEM microscopic evaluation of the MSC-Scaffold was performed using SLM manufactured prototypes and paying special attention to the quality and precision of manufacturing.
Findings – It was found that SLM can be successfully applied to manufacturing of prototypes of the original minimally invasive RHA endoprosthesis. The manufacturing quality of the 3D spikes system of the MSC-Scaffold, which mimics the interdigitations of articular subchondral bone, has been proved to be geometrically corresponding to the biological original. Nevertheless, some pores and non-melted zones were found in SLM prototyped RHA endoprosthesis cross-sections which need to be eliminated to minimize the potential risk of clinical failure.
Research limitations/implications – The presented case study was performed with a limited number of samples. More research needs to be performed on the rapid prototyped samples including microstructural and mechanical tests. The results may enable the optimization of the SLM manufacturing process of the prototypes of the minimally invasive RHA endoprosthesis with MSC-Scaffold.
Practical implications – The SLM can be considered as potentially suitable for the fabrication of patient-fitted minimally invasive RHA endoprostheses with MSC-Scaffold.
Originality/value – For the first time, largely owing to SLM technology, it was possible to manufacture the prototype of the original minimally invasive RHA endoprosthesis with MSC-Scaffold suitable for further research.
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