Review

A design for the additive

manufacture of functionally
graded porous structures with
tailored mechanical properties for
biomedical applications
Jayanthi Parthasarathy, Binil
Starly, Shivakumar Raman
Journal of Manufacturing Processes 13 (2011)
160170

Contents:
1. Introduction
1.1. Additive manufacturing of metals.
1.2. Necessity for innovative design for bone
replacement.
1.3. Periodic cellular structures and design of
internal architecture.

2. Methodology
2.1. FEA prediction of effective mechanical
properties.
2.2. Input CAD design.
2.3. Additive manufacturing electron beam
2
melting processing of Ti6Al4V.

Contents:
2.4. Evaluation of structural and mechanical
properties.
2.5. Biomechanical evaluation of patient-specific
implants.

3. Results and discussion

3.1. Predictability of structural properties.
3.2. Estimation of strength.
3.3. Performance of mandible and hip implants.

4. Conclusion
3

1. Introduction
1.1. Additive manufacturing of
metals
Additive manufacturing (AM) is defined
by ASTM as a process of joining
materials to make objects from 3D
model data, usually layer upon layer,
as opposed to subtractive
manufacturing methodologies.
Alternate names to AM include additive
fabrication, additive layer
manufacturing, layer manufacturing
and freeform fabrication.

1. Introduction
1.1. Additive manufacturing of
metals
These
processes
create
components
from
CAD
models
by
adding material
layer by layer,
and the final
components
are
often
produced in a

1. Introduction
1.1. Additive manufacturing of
metals

AM typically uses STL data

(triangulated model) of the part to be
fabricated as input data.
The CAD model of the part is sliced
into 2D layers, and each contoured
layers data is transferred onto the
machine.
Parts are built through a directed
solidification of the metal powder
using a high-energy electron beam or

2. Methodology
2.4. Evaluation of structural and
mechanical properties
Structural integrity was examined
using a micro CT scanner.
The CT image data reconstruction
software MIMICS was used to
reconstruct the 3D model of the
fabricated parts.
By analyzing the 3D model, it was
possible to determine any internal
defects, measure internal strut
dimensions, and find blocked pores.

2. Methodology
2.4. Evaluation of structural and
mechanical properties
Porosity is measured using a
pycnometer.
The effective stiffness and eventually
the compressive strength of the part
reduces with increasing porosity.

2. Methodology
2.4. Evaluation of structural and
mechanical properties
Axial compression tests were done to
evaluate the stiffness of the porous
Ti6Al4V parts.
Average values of the stiffness of the
sample groups were taken as the
stiffness value for the given porosity.
Since the parts were fabricated layer
by layer by melting of Ti6Al4V powder,
shear testing was done to evaluate the
interlayer strength.

2. Methodology
2.5. Biomechanical evaluation of
patient-specific implants
Two CAD models, a mandible and a hip
implant were used for biomechanical
evaluation.
A patient-specific 3D model of a hemi
mandible was reconstructed from CT
scan data.
Von Mises stresses generated in the
mandible as a result of vertical
masticatory forces are studied with the
elastic modulus values derived from

3. Results and discussion

3.1. Predictability of structural
properties
One of the primary interests of this
study was to determine the
predictability of the dimension of
individual structural elements and
weight of the final part.
The average measured length of the
parts is 1% more than the intended
design.
The average volume of the parts is
3.29 % over the design volume.

3. Results and discussion

3.1. Predictability of structural
properties
Using an optical microscope, 24 pores,
4 in each of the 6 sides of the cube,
were randomly selected and measured
and average values calculated.
For sets 1, 2, and 3, the struts are of the
same size, 800 m, while the distance
between the struts is increased.

3. Results and discussion

3.1. Predictability of structural
properties

3. Results and discussion

3.1. Predictability of structural
properties
Surface deformations were observed in
the optical microscope in all the
samples.
Structural deformations were also
observed in the reconstructed micro CT
images.
The surface irregularities/deformations
could be attributed to the large
variations in pore and strut sizes.

3. Results and discussion

3.1. Predictability of structural
properties
The porosities of the parts as measured
using the helium pycnometry method
for sets 14 are given in Table 4.
The estimated porosity and the
intended porosity were found to be
within acceptable limits.

3. Results and discussion

3.1. Predictability of structural
properties
The mechanical properties, especially
the strength, depend on the strut size,
apart from the overall porosity.

3. Results and discussion

3.1. Predictability of structural
properties
Mandible implant
It is observed that the sample with
maximum porosity of 70% failed at
loads of 18156 Mpa against a normal
mastication load of 180 MPa, which is
less than 20% of the ultimate tensile
strength and compressive strength,
giving a safety factor of 5.
The implant would weigh 80.57 g as
against the weight of dense titanium

4. Conclusion
A design strategy has been developed
for eventual fabrication of porous
titanium
structures
with
periodic
cellular
structures
targeted
to
biomedical applications.
Cellular structures with porosities
ranging between 49.75% and 70.32%
targeted to biomedical applications
have been designed and fabricated.
Design compensations would be
required with smaller pore sizes and

Thank You