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Cost-effective micro-CT system for non-destructive testing of titanium 3D printed medical components.

ABSTRACT: Micro-CT imaging can be used as an effective method for non-destructive testing (NDT) of metal 3D printed parts-including titanium biomedical components fabricated using laser powder-bed-fusion (LPBF). Unfortunately, the cost of commercially available micro-CT scanners renders routine NDT for biomedical applications prohibitively expensive. This study describes the design, manufacturing, and implementation of a cost-effective scanner tailored for NDT of medium-size titanium 3D printed biomedical components. The main elements of the scanner; which include a low-energy (80 kVp) portable x-ray unit, and a low-cost lens-coupled detector; can be acquired with a budget less than $ 11000 USD. The low-cost detector system uses a rare-earth phosphor screen, lens-coupled to a dSLR camera (Nikon D800) in a front-lit tilted configuration. This strategy takes advantage of the improved light-sensitivity of modern full-frame CMOS camera sensors and minimizes source-to-detector distance to maximize x-ray flux. The imaging performance of the system is characterized using a comprehensive CT quality-assurance phantom, and two titanium 3D-printed test specimens. Results show that the cost-effective scanner can survey the porosity and cracks in titanium parts with thicknesses of up to 13 mm of solid metal. Quantitatively, the scanner produced geometrically stable reconstructions, with a voxel size of 118 μm, and noise levels under 55 HU. The cost-effective scanner was able to estimate the porosity of a 17 mm diameter titanium 3D-printed cylindrical lattice structure, with a 0.3% relative error. The proposed scanner will facilitate the implementation of titanium LPBF-printed components for biomedical applications by incorporating routine cost-effective NDT as part of the process control and validation steps of medical-device quality-management systems. By reducing the cost of the x-ray detector and shielding, the scan cost will be commensurate with the overall cost of the validated component.

SUBMITTER: Cobos SF

PROVIDER: S-EPMC9550031 | biostudies-literature | 2022

REPOSITORIES: biostudies-literature

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Cost-effective micro-CT system for non-destructive testing of titanium 3D printed medical components.

Cobos Santiago Fabian SF Norley Christopher James CJ Pollmann Steven Ingo SI Holdsworth David Wayne DW

PloS one 20221010 10

Micro-CT imaging can be used as an effective method for non-destructive testing (NDT) of metal 3D printed parts-including titanium biomedical components fabricated using laser powder-bed-fusion (LPBF). Unfortunately, the cost of commercially available micro-CT scanners renders routine NDT for biomedical applications prohibitively expensive. This study describes the design, manufacturing, and implementation of a cost-effective scanner tailored for NDT of medium-size titanium 3D printed biomedical ...[more]

PMID: 36215251

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Project description:BackgroundThree-dimensional (3D) printing technology has been widely used in orthopedics; however, it is still limited to the change of macroscopic structures. In order to further improve the biological properties of 3D-printed porous titanium scaffolds, this study introduced micro-arc oxidation (MAO) technology to modify the surface of porous titanium scaffolds and construct bioactive coatings on the surface of porous titanium scaffolds to improve the biocompatibility and osseointegration ability of the material.MethodsFor in vitro experiments, human bone marrow stem cells (hBMSCs) were seeded onto untreated scaffolds (control group) and MAO-treated scaffolds (experimental group). After 24 h of co-culture, cytotoxicity was observed using live/dead staining, and cell/scaffold constructs were retrieved and processed for the assessment of cell morphology by using scanning electron microscopy (SEM). Cell proliferation was detected using the Cell Counting Kit-8 (CCK-8) assay after 3, 7, and 14 days of co-culture. The levels of alkaline phosphatase (ALP) in the cell supernatant were detected after 7 and 14 days of co-culture. For in vivo experiments, micro-computed tomography (micro-CT) and Masson Goldner's staining were used to evaluate bone ingrowth and osseointegration at 4 and 8 weeks postoperatively.ResultsIn vitro experiment results confirmed that the two groups of scaffolds were non-cytotoxic and the cell adhesion status on the MAO-treated scaffolds was better. Over time, cell proliferation and ALP levels were higher in the MAO-treated group than in the untreated scaffolds. In the in vivo experiments, the MAO-treated scaffolds showed better bone ingrowth and osseointegration than the untreated group at different time points.ConclusionsThe MAO-treated porous titanium scaffold formed a uniform and dense bioactive coating on the surface, which was more conducive to cell adhesion, proliferation, and differentiation and showed better osseointegration and bone ingrowth in vivo.

Dataset Information

Cost-effective micro-CT system for non-destructive testing of titanium 3D printed medical components.

Publications

Cost-effective micro-CT system for non-destructive testing of titanium 3D printed medical components.

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