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Dimensional variability characterization of additively manufactured lattice coupons

BACKGROUND: Additive manufacturing (AM), commonly called 3D Printing (3DP), for medical devices is growing in popularity due to the technology’s ability to create complex geometries and patient-matched products. However, due to the process variabilities which can exist between 3DP systems, manufactu...

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Autores principales: Snodderly, Kirstie Lane, Fogarasi, Magdalene, Badhe, Yutika, Parikh, Ankit, Porter, Daniel, Burchi, Albert, Gilmour, Laura, Di Prima, Matthew
Formato: Online Artículo Texto
Lenguaje:English
Publicado: Springer International Publishing 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9077930/
https://www.ncbi.nlm.nih.gov/pubmed/35523913
http://dx.doi.org/10.1186/s41205-022-00141-z
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author Snodderly, Kirstie Lane
Fogarasi, Magdalene
Badhe, Yutika
Parikh, Ankit
Porter, Daniel
Burchi, Albert
Gilmour, Laura
Di Prima, Matthew
author_facet Snodderly, Kirstie Lane
Fogarasi, Magdalene
Badhe, Yutika
Parikh, Ankit
Porter, Daniel
Burchi, Albert
Gilmour, Laura
Di Prima, Matthew
author_sort Snodderly, Kirstie Lane
collection PubMed
description BACKGROUND: Additive manufacturing (AM), commonly called 3D Printing (3DP), for medical devices is growing in popularity due to the technology’s ability to create complex geometries and patient-matched products. However, due to the process variabilities which can exist between 3DP systems, manufacturer workflows, and digital conversions, there may be variabilities among 3DP parts or between design files and final manufactured products. The overall goal of this project is to determine the dimensional variability of commercially obtained 3DP titanium lattice-containing test coupons and compare it to the original design files. METHODS: This manuscript outlines the procedure used to measure dimensional variability of 3D Printed lattice coupons and analyze the differences in external dimensions and pore area when using laser and electron beam fabricated samples. The key dimensions measured were the bulk length, width, and depth using calipers. Strut thickness and pore area were assessed for the lattice components using optical imaging and µCT. RESULTS: Results show a difference in dimensional measurement between printed parts and the computer-designed files for all groups analyzed including the internal lattice dimensions. Measurements of laser manufactured coupons varied from the nominal by less than 0.2 mm and results show averages greater than the nominal value for length, width, and depth dimensions. Measurements of Electron Beam Melting coupons varied between 0.4 mm-0.7 mm from the nominal value and showed average lengths below the nominal dimension while the width and depths were greater than the nominal values. The length dimensions of Laser Powder Bed Fusion samples appeared to be impacted by hot isostatic press more than the width and depth dimension. When lattice relative density was varied, there appeared to be little impact on the external dimensional variability for the as-printed state. CONCLUSIONS: Based on these results, we can conclude that there are relevant variations between designed files and printed parts. However, we cannot currently state if these results are clinically relevant and further testing needs to be conducted to apply these results to real-world situations.
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spelling pubmed-90779302022-05-08 Dimensional variability characterization of additively manufactured lattice coupons Snodderly, Kirstie Lane Fogarasi, Magdalene Badhe, Yutika Parikh, Ankit Porter, Daniel Burchi, Albert Gilmour, Laura Di Prima, Matthew 3D Print Med Research BACKGROUND: Additive manufacturing (AM), commonly called 3D Printing (3DP), for medical devices is growing in popularity due to the technology’s ability to create complex geometries and patient-matched products. However, due to the process variabilities which can exist between 3DP systems, manufacturer workflows, and digital conversions, there may be variabilities among 3DP parts or between design files and final manufactured products. The overall goal of this project is to determine the dimensional variability of commercially obtained 3DP titanium lattice-containing test coupons and compare it to the original design files. METHODS: This manuscript outlines the procedure used to measure dimensional variability of 3D Printed lattice coupons and analyze the differences in external dimensions and pore area when using laser and electron beam fabricated samples. The key dimensions measured were the bulk length, width, and depth using calipers. Strut thickness and pore area were assessed for the lattice components using optical imaging and µCT. RESULTS: Results show a difference in dimensional measurement between printed parts and the computer-designed files for all groups analyzed including the internal lattice dimensions. Measurements of laser manufactured coupons varied from the nominal by less than 0.2 mm and results show averages greater than the nominal value for length, width, and depth dimensions. Measurements of Electron Beam Melting coupons varied between 0.4 mm-0.7 mm from the nominal value and showed average lengths below the nominal dimension while the width and depths were greater than the nominal values. The length dimensions of Laser Powder Bed Fusion samples appeared to be impacted by hot isostatic press more than the width and depth dimension. When lattice relative density was varied, there appeared to be little impact on the external dimensional variability for the as-printed state. CONCLUSIONS: Based on these results, we can conclude that there are relevant variations between designed files and printed parts. However, we cannot currently state if these results are clinically relevant and further testing needs to be conducted to apply these results to real-world situations. Springer International Publishing 2022-05-07 /pmc/articles/PMC9077930/ /pubmed/35523913 http://dx.doi.org/10.1186/s41205-022-00141-z Text en © The Author(s) 2022 https://creativecommons.org/licenses/by/4.0/Open AccessThis article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made. The images or other third party material in this article are included in the article's Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article's Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/ (https://creativecommons.org/licenses/by/4.0/) . The Creative Commons Public Domain Dedication waiver (http://creativecommons.org/publicdomain/zero/1.0/ (https://creativecommons.org/publicdomain/zero/1.0/) ) applies to the data made available in this article, unless otherwise stated in a credit line to the data.
spellingShingle Research
Snodderly, Kirstie Lane
Fogarasi, Magdalene
Badhe, Yutika
Parikh, Ankit
Porter, Daniel
Burchi, Albert
Gilmour, Laura
Di Prima, Matthew
Dimensional variability characterization of additively manufactured lattice coupons
title Dimensional variability characterization of additively manufactured lattice coupons
title_full Dimensional variability characterization of additively manufactured lattice coupons
title_fullStr Dimensional variability characterization of additively manufactured lattice coupons
title_full_unstemmed Dimensional variability characterization of additively manufactured lattice coupons
title_short Dimensional variability characterization of additively manufactured lattice coupons
title_sort dimensional variability characterization of additively manufactured lattice coupons
topic Research
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9077930/
https://www.ncbi.nlm.nih.gov/pubmed/35523913
http://dx.doi.org/10.1186/s41205-022-00141-z
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