Novel Indirect Additive Manufacturing for Processing Biomaterials

260 Pages·2015·8.36 MB·English

Novel Indirect Additive Manufacturing
for Processing Biomaterials

Shah Fenner Khan Mohamad Khan

This dissertation is submitted for partial fulfilment for the
degree of Doctor of Philosophy.

School of Mechanical and System Engineering
Newcastle University
Newcastle upon Tyne, United Kingdom.

September 2015

Abstract

The aim of this work was to identify methods for the production of patient-specific
biomedical devices via indirect additive manufacturing (AM) methods. Additive
manufacturing has been shown to provide a good solution for the manufacture of patient
specific implants, but in a limited range of materials, and at a relatively high cost. This
research project considered what are known as “indirect” AM approaches, which typically
consider AM in combination with one or more subsequent processes in order to produce a
part, with a maxillofacial plate and mandible resection used as a demonstrator application.
Three different approaches were considered: (i) using AM to produce moulds for powder
pressing of bioceramic green parts for subsequent sintering; (ii) using AM to produce moulds
for biopolymer sintering; and (iii) 3D printing of bioceramic powders into green parts for
subsequent sintering.
Apatite wollastonite glass ceramic (AW) and poly-Lactide-co-glycolide (PLGA) were
selected as the bioceramic and biopolymer materials to process. These were characterised
before and after processing in order to ensure that the processing route did not affect the
material properties. Geometric dimensions, the morphological structure and mechanical
properties were studied to establish the accuracy, shrinkage and strength of the fabricated
biomaterial implants.
The use of AM processes to produce moulds for PLGA sintering, and the 3D printing of
bioceramic powders formed the best overall results in terms of the definition and properties of
the manufactured parts. Parts produced were accurate to within 5% of the as designed
dimensions for both the PLGA sintering and the bioceramic powders 3D printing. The
indirect AM methods are considered to be promising processing routes for medical devices.

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Dedication

This work is dedicated to my beloved late parents,
Noor Aini Abdullah
1939 – 1984
Mohamad Khan Shoumuz Khan
1937 – 2014
“Semoga Allah swt mencucuri rakhmat ke atas roh mereka.
Tiada yang mustahil dicapai sekiranya berusaha tanpa mengalah.”
Nothing is impossible to accomplish if one persevere without giving in.

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Personal statement

During the time spend in doing this research it had broadened my view as an academician as
well as a human being. Doing research is just not about academic materials purely but also
involved the interpersonal domain. How one communicates and respects others that surround
the daily activities in carrying out the research play an important and significant role in the
success of the research. The more one seek to understand one thing the more one will realise
the need to understand a lot of others related things.

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Declaration
This dissertation is the result of my work and includes nothing, which is the outcome of the
work done in collaboration except where specifically indicated in the text. It has not been
previously submitted, in part or whole, to any university of institution for any degree,
diploma, or other qualification.
In accordance with the Faculty of Science, Agriculture and Engineering guidelines, this thesis
does not exceed 80,000words.

Signed: _ _

Date: 23rd September 2015

Shah Fenner Khan Mohamad Khan MSc. (UK), BSc. (USA)
Student ID: A079082150
School of Mechanical and Systems Engineering
Newcastle University, UK.

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Acknowledgements
In the duration of my study in Newcastle University, I am ever grateful to all the individuals
who have contributed to my quest of knowledge as a Ph.D. student.
First of all, I would to extend gratitude and appreciation to my supervisors Prof. Dr. Kenneth
W. Dalgarno and Dr. Matthew German (School of Dental Sciences) for their insightful inputs,
invaluable assistance, guidance and supports throughout this research journey. This research
would not have been possible without their supervision and encouragement as supervisors and
as friends.
I too would like to express my appreciation to the technical team; Ken Madden, Malcolm
Black, Michael Foster, Stephen Charlton and Brian Stoker for all the technical assistances
and helpful advices during practical works. I would also like to thank Andrew Yates (School
of Dental Sciences) for assistance in the operation of DSC analysis and Instron tensile testing
equipment, Maggie White (School of Chemical Engineering and Advanced Materials) for
helping in XRD analysis, Pauline Carrick (ACMA) and Tracey Davey (Medical School) for
SEM works and Neville Dickman (School of Chemical Engineering and Advanced Materials)
for assistance in operation of Carbolite furnace. My gratitude also extended to Phil Heslop
(Computing Science) for 3D printing the parts that were used in the research.
I would also like to thanks to my colleagues for their suggestions, wishes and help during the
four years study.
Furthermore, I would like to thank University Malaysia Perlis and the Malaysian Higher
Education Ministry for sponsoring me and giving me the opportunity for doing research in
Newcastle University.
And most of all, I would like to express my endless love to my family for their understanding
and support through the duration of my study. Very special thanks to my children;
Nurdiyanah Nasuha, Muhammad Zulhanis, Nurliyanah Atiqah, NurIffah Syahirah and
NurIzzah Syakirah, for bringing smiles and laughter. For them, there are my sparks of
encouragement to carry on when I am down.
Finally, for my ever dearest wife, Salma Mohamad Isa for the wishes, love and support, as
well as being always by my side.
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Table of Contents
Abstract ............................................................................................................................ iii
Dedication ........................................................................................................................ iv
Personal statement ............................................................................................................ v
Declaration....................................................................................................................... vi
Acknowledgements ........................................................................................................ vii
Table of Contents ............................................................................................................ ix
List of Tables .................................................................................................................. xv
List of Figures ................................................................................................................ xvi
List of Abbreviations and Acronyms ............................................................................ xxi
Chapter 1: Introduction ..................................................................................................... 1
1.1 Introduction ............................................................................................................ 1
1.2 Research Problem ................................................................................................... 2
1.3 Research Aim and Objectives................................................................................. 4
1.3.1 Aim .................................................................................................................. 4
1.3.2 Objectives ........................................................................................................ 4
1.4 Research Framework .............................................................................................. 4
1.5 Thesis Outline ......................................................................................................... 5
Chapter 2: Literature Review ........................................................................................... 7
2.1 Introduction ............................................................................................................ 7
2.2 Fundamentals of Additive Manufacturing (AM).................................................... 7
2.3 Process categories of AM Systems ....................................................................... 10
2.3.1 Vat photopolymerisation ............................................................................... 10
2.3.2 Powder bed fusion ......................................................................................... 11
2.3.3 Directed energy deposition ............................................................................ 12
2.3.4 Binder jetting ................................................................................................. 14
2.3.5 Material Jetting .............................................................................................. 15
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2.3.6 Material Extrusion.......................................................................................... 15
2.3.7 Sheet Lamination ........................................................................................... 17
2.4 Type of Application in AM ................................................................................... 18
2.4.1 Rapid prototyping .......................................................................................... 20
2.4.2 Rapid tooling .................................................................................................. 20
2.4.3 Rapid manufacturing ...................................................................................... 21
2.5 Indirect AM ........................................................................................................... 22
2.6 Design in AM ........................................................................................................ 23
2.7 STL file format...................................................................................................... 26
2.8 Natural Bone ......................................................................................................... 28
2.8.1 Bone Graft Substitute (BGS) Materials. ........................................................ 29
2.8.2 Fixation of bone graft substitute. ................................................................... 31
2.9 Bioceramic and glass-ceramics ............................................................................. 32
2.9.1 Glass-Ceramic ................................................................................................ 34
2.9.2 Apatite Wollastonite glass-ceramics .............................................................. 37
2.10 Biodegradable polymer ....................................................................................... 39
2.10.1 Polylactide-co-Glycolide Acid (PLGA)....................................................... 43
2.11 Biocomposite ...................................................................................................... 44
2.12 Forming Processes of Biomaterials in the Manufacturing of Medical Devices
and Implants ........................................................................................................ 44
2.12.1 Fabrication methods in ceramic material ..................................................... 45
2.12.2 Methods in processing of biopolymers ........................................................ 46
2.13 Sintering .............................................................................................................. 47
2.13.1 Solid-state and liquid state sintering ............................................................ 48
2.14 Materials Characterisations and Analysis ........................................................... 50
2.14.1 Density Measurement using Pycnometer ..................................................... 51
2.14.2 DSC .............................................................................................................. 52
2.14.3 SEM ............................................................................................................. 54
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