Skip to main content

Additively Manufactured Medical Implants

  • Chapter
  • First Online:
Practical Implementations of Additive Manufacturing Technologies

Abstract

Technology has greatly advanced due to the internet and digitization, leading to the commercial production of additive manufacturing in the 2010s. This technology allows for the quick and precise creation of needed models, using a variety of materials, easily accessible printer raw supplies, no waste after production, and high production of intricate designs with precision. The digital data can be transferred quickly, and many products can be produced simultaneously in different places. These advantages have led to an increase in production with additive manufacturing. In the biomedical industry, traditional manufacturing methods cause problems with a large number of manufacturing through a single model, particularly with implants and prostheses. With additive manufacturing technology, patient-specific drug formulations, optimum dosage medicines, and patient-specific spinal, dental, hip, craniofacial implants and replacements can be manufactured with high precision. Additionally, tissues and organs can be produced via 3D printing, which helps overcoming issues such as incompatibility and a shortage of suitable donors. In this chapter, several additive manufacturing techniques and implant studies produced by these techniques have been considered in the literature, taking into account all the above aspects.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 139.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Hardcover Book
USD 179.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

References

  1. Implants and Prosthetics. https://www.fda.gov/medical-devices/products-and-medical-procedures/implants-and-prosthetics. Accessed: 03 February 2023

  2. Pandey A, Sahoo S (2023) Progress on medical implant: a review and prospects. J Bionic Eng 20(2):470–494

    Article  Google Scholar 

  3. Sunita Prem Victor CPS, Pillai CKS (2019) Biointegration: an introduction. In: Sharma CP (ed) Biointegration of medical implant materials, 2nd ed. Woodhead Publishing series in Biomaterials

    Google Scholar 

  4. Bose S, Ke D, Sahasrabudhe H, Bandyopadhyay A (2018) Additive manufacturing of biomaterials. Prog Mater Sci 93:45–111

    Article  Google Scholar 

  5. Prachi K, Kadam A (2023) Introduction and need for additive manufacturing in the medical industry. In: Banga HK, Kumar HK, Kalra P, Belokar RM (eds) Additive manufacturing with medical applications. CRC Press, Taylor & Francis Group

    Google Scholar 

  6. Darbar S, Saha S, Agarwal S (2023) Additive manufacturing market prognosis of medical devices in the international arena. In: Banga HK, Kumar HK, Kalra P, Belokar RM (eds) Additive manufacturing with medical applications. CRC Press, Taylor & Francis Group

    Google Scholar 

  7. Kumar V, Prakash C, Babbar A, Shubham Choudhary AS, Uppal (2023) Additive manufacturing in biomedical engineering present and future applications. In: Babbar A, Sharma A, Jain V, Gupta D (eds) Additive manufacturing processes in biomedical engineering advanced fabrication methods and rapid tooling techniques. CRC Press, Taylor & Francis Group

    Google Scholar 

  8. Dasgupta S, Ray S (2023) Additive manufacturing of biomaterials classification, techniques, and application. In: Babbar A, Sharma A, Jain V, Gupta D (eds) Additive manufacturing processes in biomedical engineering advanced fabrication methods and rapid tooling techniques. CRC Press, Taylor & Francis Group

    Google Scholar 

  9. ASTM International (2012) Standard terminology for additive manufacturing technologies: designation F2792-12a. ASTM International, West Conshohocken PA

    Google Scholar 

  10. Chua CK, Leong KF, An J (2020) Introduction to rapid prototyping of biomaterials. In: Narayan R (ed) Rapid prototyping of biomaterials: techniques in additive manufacturing. Woodhead Publishing

    Google Scholar 

  11. Ziaee M, Crane NB (2019) Binder jetting: a review of process, materials, and methods. Addit Manuf 28:781–801

    Google Scholar 

  12. Bandyopadhyay A, Ghosh S, Boccaccini AR, Bose S (2021) 3D printing of biomedical materials and devices. J Mater Res 36(19):3713–3724

    Article  Google Scholar 

  13. Lam CXF, Mo XM, Teoh SH, Hutmacher DW (2002) Scaffold development using 3D printing with a starch-based polymer. Mater Sci Eng C 20(1):49–56

    Article  Google Scholar 

  14. Mostafaei A et al (2021) Binder jet 3D printing—process parameters, materials, properties, modeling, and challenges. Prog Mater Sci 119:100707

    Article  Google Scholar 

  15. Leukers B et al (2005) Hydroxyapatite scaffolds for bone tissue engineering made by 3D printing. J Mater Sci Mater Med 16(12):1121–1124

    Article  Google Scholar 

  16. Sheydaeian E, Ibhadode OO, Hu E, Pilliar R, Kandel R, Toyserkani E (2021) Additive manufacture of porous ceramic proximal interphalangeal (PIP) joint implant: design and process optimization. Int J Adv Manuf Technol 115(9):2825–2837

    Article  Google Scholar 

  17. Wu C et al (2012) 3D-printing of highly uniform CaSiO3 ceramic scaffolds: preparation, characterization and in vivo osteogenesis. J Mater Chem 22(24):12288–12295

    Article  Google Scholar 

  18. Miyanaji H, Zhang S, Lassell A, Zandinejad A, Yang L (2016) Process development of porcelain ceramic material with binder jetting process for dental applications. JOM 68(3):831–841

    Article  Google Scholar 

  19. Klammert U, Gbureck U, Vorndran E, Rödiger J, Meyer-Marcotty P, Kübler AC (2010) 3D powder printed calcium phosphate implants for reconstruction of cranial and maxillofacial defects. J Cranio-Maxillofacial Surg 38(8):565–570

    Article  Google Scholar 

  20. Fielding GA, Bandyopadhyay A, Bose S (2012) Effects of silica and zinc oxide doping on mechanical and biological properties of 3D printed tricalcium phosphate tissue engineering scaffolds. Dent Mater 28(2):113–122

    Article  Google Scholar 

  21. Inzana JA et al (2014) 3D printing of composite calcium phosphate and collagen scaffolds for bone regeneration. Biomaterials 35(13):4026–4034

    Article  Google Scholar 

  22. Sheydaeian E, Fishman Z, Vlasea M, Toyserkani E (2017) On the effect of throughout layer thickness variation on properties of additively manufactured cellular titanium structures. Addit Manuf 18:40–47

    Google Scholar 

  23. Kuah KX et al (2022) Analysis of the corrosion performance of binder jet additive manufactured magnesium alloys for biomedical applications. J Magnes Alloy 10(5):1296–1310

    Article  Google Scholar 

  24. Seitz H, Rieder W, Irsen S, Leukers B, Tille C (2005) Three-dimensional printing of porous ceramic scaffolds for bone tissue engineering. J Biomed Mater Res Part B Appl Biomater 74B(2):782–788

    Google Scholar 

  25. Wiria FE, Shyan JYM, Lim PN, Wen FGC, Yeo JF, Cao T (2010) Printing of Titanium implant prototype. Mater Des 31:S101–S105

    Article  Google Scholar 

  26. Chou D-T, Wells D, Hong D, Lee B, Kuhn H, Kumta PN (2013) Novel processing of iron–manganese alloy-based biomaterials by inkjet 3-D printing. Acta Biomater 9(10):8593–8603

    Article  Google Scholar 

  27. Bergmann C et al (2010) 3D printing of bone substitute implants using calcium phosphate and bioactive glasses. J Eur Ceram Soc 30(12):2563–2567

    Article  Google Scholar 

  28. Zhang X, Liou F (2021) Introduction to additive manufacturing. In: Pou F, Riveiro A, Davim JPBT-AM (eds) Handbooks in advanced manufacturing. Elsevier, pp 1–31

    Google Scholar 

  29. Kumar S (2020) Laser powder bed fusion. In: Kumar S (ed) Additive manufacturing processes. Springer Nature Switzerland AG 2020

    Google Scholar 

  30. Gokuldoss PK, Kolla S, Eckert J (2017) Additive manufacturing processes: selective laser melting, electron beam melting and binder jetting—selection guidelines. Materials 10(6)

    Google Scholar 

  31. Ataee A, Li Y, Brandt M, Wen C (2018) Ultrahigh-strength titanium gyroid scaffolds manufactured by selective laser melting (SLM) for bone implant applications. Acta Mater 158:354–368

    Article  Google Scholar 

  32. Zumofen L, Kopanska KS, Bono E, Kirchheim A, De Haller EB, Graf-Hausner (2022) Properties of additive-manufactured open porous titanium structures for patient-specific load-bearing implants. Front Mech Eng 7

    Google Scholar 

  33. Velásquez-García LF, Kornbluth Y (2021) Biomedical applications of metal 3D printing. Annu Rev Biomed Eng 23(1):307–338

    Article  Google Scholar 

  34. Sing SL, Yeong WY, Wiria FE (2016) Selective laser melting of titanium alloy with 50 wt% tantalum: microstructure and mechanical properties. J Alloys Compd 660:461–470

    Article  Google Scholar 

  35. Soro N, Attar H, Brodie E, Veidt M, Molotnikov A, Dargusch MS (2019) Evaluation of the mechanical compatibility of additively manufactured porous Ti–25Ta alloy for load-bearing implant applications. J Mech Behav Biomed Mater 97:149–158

    Article  Google Scholar 

  36. Soro N, Brodie EG, Abdal-hay A, Alali AQ, Kent D, Dargusch MS (2022) Additive manufacturing of biomimetic Titanium-Tantalum lattices for biomedical implant applications. Mater Des 218:110688

    Article  Google Scholar 

  37. Ackers MA, Messé OMDM, Manninen N, Stryzhyboroda O, Hecht U (2022) Additive manufacturing of TTFNZ (Ti-4.5Ta-4Fe-7.5Nb-6Zr), a novel metastable β-titanium alloy for advanced engineering applications. J Alloys Compd 920:165899

    Article  Google Scholar 

  38. Zhou Z, Liu Y, Liu X, Zhan Q, Wang K (2021) Microstructure evolution and mechanical properties of in-situ Ti6Al4V–TiB composites manufactured by selective laser melting. Compos Part B Eng 207:108567

    Article  Google Scholar 

  39. Hou C et al (2022) Additive manufacturing of functionally graded porous titanium scaffolds for dental applications. Biomater Adv 139:213018

    Article  Google Scholar 

  40. Xu W et al (2022) Gyroid-based functionally graded porous titanium scaffolds for dental application: design, simulation and characterizations. Mater Des 224:111300

    Article  Google Scholar 

  41. Selvaraj S, Dorairaj J, Shivasankar M, Mission V, College D (2022) 3D cranial reconstruction using titanium implant – a case report. 22(3):383–390

    Google Scholar 

  42. McGee OM et al (2022) An investigation into patient-specific 3D printed titanium stents and the use of etching to overcome selective laser melting design constraints. J Mech Behav Biomed Mater 134:105388

    Article  Google Scholar 

  43. Bai L et al (2019) Additive manufacturing of customized metallic orthopedic implants: materials, structures, and surface modifications. Metals 9(9)

    Google Scholar 

  44. Čapek J et al (2016) Highly porous, low elastic modulus 316L stainless steel scaffold prepared by selective laser melting. Mater Sci Eng C 69:631–639

    Article  Google Scholar 

  45. Jiang C-P, Wibisono AT, Pasang T (2021) Selective laser melting of stainless steel 316L with face-centered-cubic-based lattice structures to produce rib implants. Materials 14(20)

    Google Scholar 

  46. Han C et al (2017) Effects of the unit cell topology on the compression properties of porous Co-Cr scaffolds fabricated via selective laser melting. Rapid Prototyp J 23(1):16–27

    Article  Google Scholar 

  47. Hedberg YS, Qian B, Shen Z, Virtanen S, Odnevall Wallinder I (2014) In vitro biocompatibility of CoCrMo dental alloys fabricated by selective laser melting. Dent Mater 30(5):525–534

    Google Scholar 

  48. Wei D, Koizumi Y, Takashima T, Nagasako M, Chiba A (2018) Fatigue improvement of electron beam melting-fabricated biomedical Co–Cr–Mo alloy by accessible heat treatment. Mater Res Lett 6(1):93–99

    Google Scholar 

  49. Chen W et al (2021) Fatigue behaviour and biocompatibility of additively manufactured bioactive tantalum graded lattice structures for load-bearing orthopaedic applications. Mater Sci Eng C 130:112461

    Article  Google Scholar 

  50. Chua K, Khan I, Malhotra R, Zhu D (2021) Additive manufacturing and 3D printing of metallic biomaterials. Eng Regen 2:288299

    Google Scholar 

  51. Čapek J, Kubásek J, Vojtěch D, Jablonská E, Lipov J, Ruml T (2016) Microstructural, mechanical, corrosion and cytotoxicity characterization of the hot forged FeMn30 (wt%) alloy. Mater Sci Eng C 58:900–908

    Article  Google Scholar 

  52. Hufenbach J, Wendrock H, Kochta F, Kühn U, Gebert A (2017) Novel biodegradable Fe-Mn-C-S alloy with superior mechanical and corrosion properties. Mater Lett 186:330–333

    Article  Google Scholar 

  53. Venezuela J, Dargusch MS (2020) Addressing the slow corrosion rate of biodegradable Fe-Mn: current approaches and future trends. Curr Opin Solid State Mater Sci 24(3):100822

    Article  Google Scholar 

  54. Nie Y et al (2021) In vitro and 48 weeks in vivo performances of 3D printed porous Fe-30Mn biodegradable scaffolds. Acta Biomater 121:724–740

    Article  Google Scholar 

  55. Liu R-Y, He R-G, Xu L-Q, Guo S-F (2018) Design of Fe–Mn–Ag alloys as potential candidates for biodegradable metals. Acta Metall Sin (English Lett) 31(6):584–590

    Google Scholar 

  56. Liu B, Zheng YF, Ruan L (2011) In vitro investigation of Fe30Mn6Si shape memory alloy as potential biodegradable metallic material. Mater Lett 65(3). Elsevier B.V.

    Google Scholar 

  57. Dehghan-Manshadi A, Venezuela J, Demir AG, Ye Q, Dargusch MS (2022) Additively manufactured Fe-35Mn-1Ag lattice structures for biomedical applications. J Manuf Process 80:642–650

    Article  Google Scholar 

  58. Gao C, Zeng Z, Peng S, Shuai C (2022) Magnetostrictive bulk Fe-Ga alloys prepared by selective laser melting for biodegradable implant applications. Mater Des 220:110861

    Article  Google Scholar 

  59. Dvorský D et al (2021) The effect of powder size on the mechanical and corrosion properties and the ignition temperature of WE43 alloy prepared by spark plasma sintering. J Magnes Alloy 9(4):1349–1362

    Article  Google Scholar 

  60. Kalb H, Rzany A, Hensel B (2012) Impact of microgalvanic corrosion on the degradation morphology of WE43 and pure magnesium under exposure to simulated body fluid. Corros Sci 57:122–130

    Article  Google Scholar 

  61. Lovašiová P et al (2022) Biodegradable WE43 magnesium alloy produced by selective laser melting: mechanical properties, corrosion behavior, and in-vitro cytotoxicity. Metals 12(3)

    Google Scholar 

  62. Xie K et al (2022) Additively manufactured biodegradable porous magnesium implants for elimination of implant-related infections: an in vitro and in vivo study. Bioact Mater 8:140–152

    Article  Google Scholar 

  63. Zheng YF, Gu XN, Witte F (2014) Biodegradable metals. Mater Sci Eng R Rep 77:1–34

    Article  Google Scholar 

  64. Wang C, Hu Y, Zhong C, Lan C, Li W, Wang X (2022) Microstructural evolution and mechanical properties of pure Zn fabricated by selective laser melting. Mater Sci Eng A 846:143276

    Article  Google Scholar 

  65. Shuai C et al (2021) Mechanically driving supersaturated Fe–Mg solid solution for bone implant: preparation, solubility and degradation. Compos Part B Eng 207:108564

    Article  Google Scholar 

  66. Liu L, Ma H, Gao C, Shuai C, Peng S (2020) Island-to-acicular alteration of second phase enhances the degradation resistance of biomedical AZ61 alloy. J Alloys Compd 835:155397

    Article  Google Scholar 

  67. Yang Y et al (2021) Rare earth improves strength and creep resistance of additively manufactured Zn implants. Compos Part B Eng 216:108882

    Article  Google Scholar 

  68. Jamshidi P et al (2022) Development, characterisation, and modelling of processability of nitinol stents using laser powder bed fusion. J Alloys Compd 909:164681

    Article  Google Scholar 

  69. Chaudhary R, Fabbri P, Leoni E, Mazzanti F, Akbari R, Antonini C (2022) Additive manufacturing by digital light processing: a review. Prog Addit Manuf

    Google Scholar 

  70. Germaini M-M, Belhabib S, Guessasma S, Deterre R, Corre P, Weiss P (2022) Additive manufacturing of biomaterials for bone tissue engineering—a critical review of the state of the art and new concepts. Prog Mater Sci 130:100963

    Article  Google Scholar 

  71. Zhou T et al (2020) SLA 3D printing of high quality spine shaped β-TCP bioceramics for the hard tissue repair applications. Ceram Int 46(6):7609–7614

    Article  Google Scholar 

  72. Chen F et al (2020) Preparation and biological evaluation of ZrO2 all-ceramic teeth by DLP technology. Ceram Int 46(8), Part A:11268–11274

    Google Scholar 

  73. Oladapo BI et al (2021) 3D printing of PEEK–cHAp scaffold for medical bone implant. Bio-Design Manuf 4(1):44–59

    Article  Google Scholar 

  74. Yang Y et al (2022) 3D-printed polycaprolactone-chitosan based drug delivery implants for personalized administration. Mater Des 214:110394

    Article  Google Scholar 

  75. Lotfizarei Z, Mostafapour A, Barari A, Jalili A, Patterson AE (2023) Overview of debinding methods for parts manufactured using powder material extrusion. Addit Manuf 61:103335

    Google Scholar 

  76. Rane K, Strano M (2019) A comprehensive review of extrusion-based additive manufacturing processes for rapid production of metallic and ceramic parts. Adv Manuf 7(2):155–173

    Article  Google Scholar 

  77. Nötzel D, Eickhoff R, Hanemann T (2018) Fused filament fabrication of small ceramic components. Materials 11(8)

    Google Scholar 

  78. Dairaghi J et al (2022) 3D printing of human Ossicle models for the biofabrication of personalized middle ear prostheses. Appl Sci 12(21)

    Google Scholar 

  79. Slámečka K et al (2023) Fatigue behaviour of titanium scaffolds with hierarchical porosity produced by material extrusion additive manufacturing. Mater Des 225:111453

    Article  Google Scholar 

  80. Shaikh MQ et al (2021) Investigation of patient-specific maxillofacial implant prototype development by metal fused filament fabrication (MF(3)) of Ti-6Al-4V. Dent J 9(10)

    Google Scholar 

  81. Antoniac I, Popescu D, Zapciu A, Antoniac A, Miculescu F, Moldovan H (2019) Magnesium filled polylactic acid (PLA) material for filament based 3D printing. Materials 12(5)

    Google Scholar 

  82. Xu C, Yu S, Wu W, Liu Q, Ren L (2022) Direct ink writing of Fe bone implants with independently adjustable structural porosity and mechanical properties. Addit Manuf 51:102589

    Google Scholar 

Download references

Acknowledgements

This work was financially supported by Zonguldak Bülent Ecevit University, Scientific Research Projects Coordination Department, under project no: 2022-73338635-01.

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Baris Avar .

Editor information

Editors and Affiliations

Rights and permissions

Reprints and permissions

Copyright information

© 2024 The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.

About this chapter

Check for updates. Verify currency and authenticity via CrossMark

Cite this chapter

Dağ, I.E., Avar, B. (2024). Additively Manufactured Medical Implants. In: Rajendrachari, S. (eds) Practical Implementations of Additive Manufacturing Technologies. Materials Horizons: From Nature to Nanomaterials. Springer, Singapore. https://doi.org/10.1007/978-981-99-5949-5_11

Download citation

  • DOI: https://doi.org/10.1007/978-981-99-5949-5_11

  • Published:

  • Publisher Name: Springer, Singapore

  • Print ISBN: 978-981-99-5948-8

  • Online ISBN: 978-981-99-5949-5

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics