Rapid Prototyping Journal, Volume 21, Issue 1, January 2015.
Purpose The paper presents how customized implants could be made with specific properties, by setting different values of the laser power, within the Selective Laser Melting (SLM) process. A detailed case study was undertaken and a new multi-structured femoral prosthesis was designed and analyzed, in order to simulate its behavior for a specific case study. Design/methodology/approach The materials and manufacturing methods are presented, with details regarding the SLM process, using the Realizer 250 machine. The laser power was varied between 50W–200W, thus obtaining samples with different physical and mechanical characteristics. All those sample parts were characterized and their properties were measured. Findings A practical methodology to produce multi-structured implants by SLM. Significant changes of the porosity and properties were found, when modifying the laser power at the SLM machine. The studies have indicated an open porosity varying between 24.81% and 0.83%. Tensile tests of the samples showed Young’s module values varying between 13.5 and 104.5 GPa and an ultimate stress between 20.2 and 497.5 MPa. Research limitations/implications There is no AM machine available, to work with different laser power values, in different regions of the same section of the implant. That is why, it cannot be obtained a multi structured implant, directly. Practical implications The prosthesis should be specifically designed, in order to contain separate models/regions to be made with appropriate laser power values. Originality/value Presents a new method to design and manufacture a multi-structured implant, using the existing AM equipment. A detailed case study is presented, showing the design procedure, the way to simulate its behavior and the methods to produce the implants by SLM.
Purpose The paper presents how customized implants could be made with specific properties, by setting different values of the laser power, within the Selective Laser Melting (SLM) process. A detailed case study was undertaken and a new multi-structured femoral prosthesis was designed and analyzed, in order to simulate its behavior for a specific case study. Design/methodology/approach The materials and manufacturing methods are presented, with details regarding the SLM process, using the Realizer 250 machine. The laser power was varied between 50W–200W, thus obtaining samples with different physical and mechanical characteristics. All those sample parts were characterized and their properties were measured. Findings A practical methodology to produce multi-structured implants by SLM. Significant changes of the porosity and properties were found, when modifying the laser power at the SLM machine. The studies have indicated an open porosity varying between 24.81% and 0.83%. Tensile tests of the samples showed Young’s module values varying between 13.5 and 104.5 GPa and an ultimate stress between 20.2 and 497.5 MPa. Research limitations/implications There is no AM machine available, to work with different laser power values, in different regions of the same section of the implant. That is why, it cannot be obtained a multi structured implant, directly. Practical implications The prosthesis should be specifically designed, in order to contain separate models/regions to be made with appropriate laser power values. Originality/value Presents a new method to design and manufacture a multi-structured implant, using the existing AM equipment. A detailed case study is presented, showing the design procedure, the way to simulate its behavior and the methods to produce the implants by SLM.