IADR Abstract Archives
Metal/Polymer-Combined 3D Printing and Lightweight High-Strength Mandibular Implant
Objectives: The goal of this study is to develop new 3D printing technology, metal-resin multiphase 3D printing, for lightweight high-strength and biocompatible mandible implants. We synthesize new multifunctional biocomposites using methacrylate-based photocurable dental resins and biocompatible micro-/nano-fillers, such as nano-hydroxyapatites (nHAPs) and silica particulates, which are adopted to fabricate implants utilizing newly developed 3D printing technology.
Methods: The dental resin-based biocomposites comprise a photocurable monomer system such as a mixture of methacrylate monomers and 5-20 wt.% of the micro-/nano-filler system containing nHAPs and silica particulates. 3D-printed Ti alloy (Ti-6Al-4V) plates with various thicknesses ranging 300-800 µm are fabricated using metallic SLS printing. Surface modification on Ti alloy by Al2O3 atomic layer deposition (ALD) and silane grafting is performed to improve the interfacial bonding between Ti alloy and resin. The 3D-printed implants are post-processed under the atmospheric cold plasma, which textures the surface by exposing the nano-fillers and provides a much higher bioactive surface leading to increased osteoconductive and osteoinductive activity.
Results: With the increasing filler fraction, the values of the compressive strength and modulus of the 3D-printed composites showed increases of 16.5% and 56.4%, respectively. The cold plasma treatment of the biocomposites resulted in a nanotextured surface and the hydrophobic surface characteristic transformed to hydrophilic due to the exposure of nHAPs to the outer surface. They exhibited better cell (MC3T3-E1) adhesion and proliferation capacities. Then, Ti-embedded biocomposite implants were successfully fabricated using metal-polymer 3D printing. Their specific strength (strength/density) increased up to 200% compared to the jaw bone and PEEK.
Conclusions: Synthetic mandible implants are fabricated using multifunctional biocomposites and the combined-3D fabrication method and they show lightweight high-strength, metal-contact-free, and good biocompatibility and osteogenic characteristics. The ALD on 3D-printed titanium alloy and cold plasma treatment on the implants contribute to improving the mechanical, physical, and biological properties of synthesized implants.
Methods: The dental resin-based biocomposites comprise a photocurable monomer system such as a mixture of methacrylate monomers and 5-20 wt.% of the micro-/nano-filler system containing nHAPs and silica particulates. 3D-printed Ti alloy (Ti-6Al-4V) plates with various thicknesses ranging 300-800 µm are fabricated using metallic SLS printing. Surface modification on Ti alloy by Al2O3 atomic layer deposition (ALD) and silane grafting is performed to improve the interfacial bonding between Ti alloy and resin. The 3D-printed implants are post-processed under the atmospheric cold plasma, which textures the surface by exposing the nano-fillers and provides a much higher bioactive surface leading to increased osteoconductive and osteoinductive activity.
Results: With the increasing filler fraction, the values of the compressive strength and modulus of the 3D-printed composites showed increases of 16.5% and 56.4%, respectively. The cold plasma treatment of the biocomposites resulted in a nanotextured surface and the hydrophobic surface characteristic transformed to hydrophilic due to the exposure of nHAPs to the outer surface. They exhibited better cell (MC3T3-E1) adhesion and proliferation capacities. Then, Ti-embedded biocomposite implants were successfully fabricated using metal-polymer 3D printing. Their specific strength (strength/density) increased up to 200% compared to the jaw bone and PEEK.
Conclusions: Synthetic mandible implants are fabricated using multifunctional biocomposites and the combined-3D fabrication method and they show lightweight high-strength, metal-contact-free, and good biocompatibility and osteogenic characteristics. The ALD on 3D-printed titanium alloy and cold plasma treatment on the implants contribute to improving the mechanical, physical, and biological properties of synthesized implants.
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