Optimised Method for 3D Printing Reliable and Biocompatible Diamond Titanium Microstrut Array for Medical Implants Using Laser Metal Deposition

Abstract

Bone is prone to many complicated diseases and injuries. Hence, implant engineering is a critical healthcare challenge that addresses the increased need to efficiently replace the damaged tissue with functional bone-mimicking devices and mechanically reliable customised implants. Additive manufacturing (AM) offers a platform to fabricate customised patient-specific parts. However, despite favourable customisation outcomes, relatively few AM feedstock powders offer the biocompatibility required for medical implant and devices technologies. The process of developing feedstock that can be 3D printed into specific 3D structures while providing a favourable interface with the human tissue remains a challenge. Diamond-titanium (DTi) is a new composite that provides biocompatible 3D multi-material structures. Thus, we report herein a powder-deposition and print optimisation strategy to overcome the dual-functionality gap by printing bulk DTi parts. First, we provide details of the composite powder properties, flow analysis and printing-specific condition optimisation. Later we report structural integrity using Micro-CT and nanoindentation. We provide details of the design of the first 3D printed micro struts. Our approach offers a clear strategy to manufacture DTi parts with high integrity, performance, and biocompatibility, consequently expanding the material feedstock library and paving the way to diamond customised implants.

Keywords: Diamond, 3D printing, feedstock, osteoblast, Implants