Metal fused filament fabrication (MF3) of Ti-6Al-4 V implants by using flexible, partially water-soluble binder systems

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design Pub Date : 2025-05-10 DOI:10.1016/j.matdes.2025.114088

Ralf Eickhoff , Steffen Antusch , Dorit Nötzel , Thomas Hanemann

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Abstract

Metal Fused Filament Fabrication provides a cost-efficient method to produce metal implants adapted to the patient. However, the limited flexibility of highly filled filaments and the reduced accuracy in comparison with alternative additive manufacturing techniques currently restrict the widespread implementation of this method. Building upon the findings of previous studies, the eco-friendly partially water-soluble binder systems containing polyethylene glycol (PEG), poly(vinylbutyral) (PVB) and poly(methylmethacrylat) (PMMA) were further optimized. Consequently, the influence of the plasticizer acetyltributylcitrate (ATBC) on the flow behavior and the flexibility of the filaments was investigated. The combination of all binder components, in conjunction with a solids content of 60 %, has enabled the fabrication of filaments with a high degree of usability, attributable to their remarkable flexibility and excellent printing properties. Following the debinding and sintering processes, the manufacturing of implants with densities that exceed 99.5 % of the theoretical values was feasible.

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采用柔性部分水溶性粘结剂体系制备ti - 6al - 4v植入物的金属熔丝（MF3）

金属熔丝制造提供了一种经济有效的方法来生产适合患者的金属植入物。然而，与其他增材制造技术相比，高度填充长丝的有限灵活性和降低的精度目前限制了该方法的广泛实施。在前人研究成果的基础上，进一步优化了聚乙二醇（PEG）、聚乙烯基丁醛（PVB）和聚甲基丙烯酸甲酯（PMMA）的环保型部分水溶性粘结剂体系。因此，研究了增塑剂乙酰三丁酸酯（ATBC）对长丝流动性能和柔韧性的影响。所有粘结剂成分的组合，再加上60%的固体含量，使长丝的制造具有高度的可用性，这归功于它们卓越的灵活性和优异的印刷性能。通过脱脂和烧结工艺，可以制造出密度超过理论值99.5%的植入物。

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来源期刊

Materials & Design Engineering-Mechanical Engineering

CiteScore

14.30

自引率

7.10%

发文量

1028

审稿时长

85 days

期刊介绍： Materials and Design is a multi-disciplinary journal that publishes original research reports, review articles, and express communications. The journal focuses on studying the structure and properties of inorganic and organic materials, advancements in synthesis, processing, characterization, and testing, the design of materials and engineering systems, and their applications in technology. It aims to bring together various aspects of materials science, engineering, physics, and chemistry. The journal explores themes ranging from materials to design and aims to reveal the connections between natural and artificial materials, as well as experiment and modeling. Manuscripts submitted to Materials and Design should contain elements of discovery and surprise, as they often contribute new insights into the architecture and function of matter.