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Design and additive manufacturing of porous orthopaedic implants

1/7/2016

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Orthopaedic regenerative medicine requires the design of scaffolds and implants that replicate the biomechanical properties of bones. Porous implants, designed with bespoke mechanical performance using state-of-the-art of topology optimization and produced by additive manufacturing, are suitable candidates for repairing or replacing damaged bones. 

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Metallic microlattices and applications

20/5/2016

 
Lattice materials with dimensions close to micrometer scale are called microlattices. 

They can be produced from different materials [1] such as composites, polymers and metals.  

Here we focus solely on metallic microlattices and their manufacture, mechanical properties and possible applications.
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SLM process control - pre-processing of reactive aluminium powders to minimise porosity

15/4/2016

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A few months ago, we were wondering about process control in powder bed fusion of reactive powders. What are the impacts of particles’ surface contamination on the fabrication of metal components? And what are the best ways to minimise it during the complete manufacturing cycle?
 
Then, very few studies were trying to assess the impact of powder particles surface chemistry on the process (powder spreading, melt wettability, pores formation, etc…) and on the final product characteristics (relative density, etc).
 
As more data get publicly available, we can present the results of a detailed investigation aiming to 1) understand the effects of powder surface chemistry, 2) minimise particles surface contamination on the finished products and 3) improve SLM process control.

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Effect of particles size distribution and packing density on the formation of balling defects during SLM of In718

27/11/2015

 
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Laser-powder bed fusion (L-PBF) is an additive manufacturing technology that involves complex physical processes. Beam absorptance, heat transfer and molten metal flowS, phase transformation, and thermal stress and distortion combine to influence the final build quality and properties [1-3].
Balling is a defect that can occur when the molten pool created during selective laser melting (SLM=L-PBF) becomes discontinuous and breaks into separated islands. In this post, we report and discuss how the powder particle arrangement impact the bead geometry and formation of balling defects during SLM.

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Residual stress in metal components built using laser direct deposition

20/11/2015

 
Direct Laser Deposition (DLD) is a type of laser-based additive manufacturing process used to create functional metal components layer by layer using a sliced 3D CAD (computer aided drawing) file. Unlike Selective Laser Melting which utilizes a bed of powder metal that is ‘selectively’ melted via a laser, DLD is based on melting feedstock (blown powder or wire) at the focus point of a laser source. In this post, we address the residual stresses occurring during the build of metal components with DLD technology [1].

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