Laser polished fused deposition poly-lactic acid objects for personalized orthopaedic application
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Laser polished fused deposition poly‑lactic acid objects for personalized orthopaedic application Yuan Chai1 · Xiao‑Bo Chen2 · Donghai Zhang1 · Joseph Lynch1 · Nick Birbilis3 · Qing‑Hua Qin3 · Paul N. Smith4 · Rachel W. Li1,5 Received: 26 June 2020 / Accepted: 7 October 2020 © The Author(s) 2020 OPEN
Abstract Patient-specific surgical guides are increasingly demanded. Material Extrusion (ME) is a popular 3D printing technique to fabricate personalized surgical guides. However, the ME process usually generates deleterious surface topography which is not suitable for orthopaedic emergencies. We designed and optimized parametric combinations of a laser polishing approach as post process to improve the surface quality of ME-made poly-lactic acid (PLA) objects. In this study, we investigated the contribution of processing variables to the mechanical properties and the biocompatibilities in vitro of the ME-made PLA objects. Conventional surface grinding was conducted as comparison. The results demonstrate that the ME-made PLA samples exhibit good mechanical properties and favourable biocompatibility after being post processed using laser polishing. The post laser polishing, as a powerful tool in manufacture of ME-made PLA objects, will open a new approach with a great promise in its applications in personalized and timely management of medical emergencies. Keywords Biocompatibility · Fused deposition modelling · Mechanical strength · Orthopaedics · Surgical guide · Three dimensional printing
1 Introduction Orthopaedic implants and surgical guides are usually standardized products that are categorized into a limited number of sizes to fit all patients [1]. However, bone geometrical and structural parameters and the complexity of a traumatic injury or joint reconstruction vary individually [2, 3]. Consequently, the geometric mismatch between a surgical device and individual bone increases the possibility of nerve roots or visceral damage [4, 5], biomechanical disadvantages [6], implant mobility and loosening [7], and implant failure [8]. Good fitting accuracy of implants or surgical guides will reduce the risk of body rejection and
complications, and influence on the osseointegration at the interface between bone and implants after surgery, which will largely improve clinical outcomes. Therefore, customized patient-specific medical implants with an accurate implant configuration and appropriate implant placement have become attractive [9]. Likewise, patientspecific surgical guides are increasingly demanded, particularly by orthopaedic surgeons worldwide in planning their surgeries and improving the accuracy during their performances [10]. Three-dimensional (3D) printing, a modern additive manufacturing technology, emerges as asimple and feasible solution to the manufacturing issue related to
* Rachel W. Li, [email protected] | 1Trauma and Orthopaedic Research Laboratory, Department of Surgery, The Medical School, The Australian National University, Canberra, ACT 2601, Australia. 2School of Engineering, RMIT Uni
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