Experimental analysis and numerical fatigue life prediction of 3D-Printed osteosynthesis plates
The trend towards patient-specific medical orthopedic prostheses has led to an increased use of 3D-printed surgical implants made of Ti6Al4V. However, uncertainties arise due to varying printing parameters, particularly with regards to the fatigue limit. This necessitates time-consuming and costly e...
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| Format: | Article |
| Language: | English |
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Frontiers Media S.A.
2023-03-01
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| Series: | Frontiers in Bioengineering and Biotechnology |
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| Online Access: | https://www.frontiersin.org/articles/10.3389/fbioe.2023.1133869/full |
| _version_ | 1797866045070901248 |
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| author | Mohsen Nakhaei Manon Sterba Jean-Marc Foletti Jean-Marc Foletti Laurent Badih Michel Behr |
| author_facet | Mohsen Nakhaei Manon Sterba Jean-Marc Foletti Jean-Marc Foletti Laurent Badih Michel Behr |
| author_sort | Mohsen Nakhaei |
| collection | DOAJ |
| description | The trend towards patient-specific medical orthopedic prostheses has led to an increased use of 3D-printed surgical implants made of Ti6Al4V. However, uncertainties arise due to varying printing parameters, particularly with regards to the fatigue limit. This necessitates time-consuming and costly experimental validation before they can be safely used on patients. To address this issue, this study aimed to employ a stress-life fatigue analysis approach coupled with a finite element (FE) simulation to estimate numerically the fatigue limit and location of failure for 3D-printed surgical osteosynthesis plates and to validate the results experimentally. However, predicting the fatigue life of 3D components is not a new concept and has previously been implemented in the medical device field, though without experimental validation. Then, an experimental fatigue test was conducted using a proposed modification to the staircase method introduced in ISO 12107. Additionally, a FE model was developed to estimate the stress cycles on the plate. The stress versus number of cycles to failure curve (S-N) obtained from the minimum mechanical properties of 3D-printed Ti6AI4V alloy according to ASTM F3001-14 to predict the fatigue limit. The comparison between experimental results and fatigue numerical predictions showed very good agreement. It was found that a linear elastic FE model was sufficient to estimate the fatigue limit, while an elastic-plastic model led to an accurate prediction throughout the implant’s cyclic life. The proposed method has great potential for enhancing patient-specific implant designs without the need for time-consuming and costly experimental regulatory testing. |
| first_indexed | 2024-04-09T23:18:46Z |
| format | Article |
| id | doaj.art-a76e23cefa5444d8a7296e8c8b77afe2 |
| institution | Directory Open Access Journal |
| issn | 2296-4185 |
| language | English |
| last_indexed | 2024-04-09T23:18:46Z |
| publishDate | 2023-03-01 |
| publisher | Frontiers Media S.A. |
| record_format | Article |
| series | Frontiers in Bioengineering and Biotechnology |
| spelling | doaj.art-a76e23cefa5444d8a7296e8c8b77afe22023-03-22T05:08:23ZengFrontiers Media S.A.Frontiers in Bioengineering and Biotechnology2296-41852023-03-011110.3389/fbioe.2023.11338691133869Experimental analysis and numerical fatigue life prediction of 3D-Printed osteosynthesis platesMohsen Nakhaei0Manon Sterba1Jean-Marc Foletti2Jean-Marc Foletti3Laurent Badih4Michel Behr5Glad Medical SAS, Salon De Provence, FranceGlad Medical SAS, Salon De Provence, FranceAix Marseille Université, Université Gustave Eiffel, LBA, Marseille, FranceAssistance Publique, Hôpitaux de Marseille, Marseille, FranceGlad Medical SAS, Salon De Provence, FranceAix Marseille Université, Université Gustave Eiffel, LBA, Marseille, FranceThe trend towards patient-specific medical orthopedic prostheses has led to an increased use of 3D-printed surgical implants made of Ti6Al4V. However, uncertainties arise due to varying printing parameters, particularly with regards to the fatigue limit. This necessitates time-consuming and costly experimental validation before they can be safely used on patients. To address this issue, this study aimed to employ a stress-life fatigue analysis approach coupled with a finite element (FE) simulation to estimate numerically the fatigue limit and location of failure for 3D-printed surgical osteosynthesis plates and to validate the results experimentally. However, predicting the fatigue life of 3D components is not a new concept and has previously been implemented in the medical device field, though without experimental validation. Then, an experimental fatigue test was conducted using a proposed modification to the staircase method introduced in ISO 12107. Additionally, a FE model was developed to estimate the stress cycles on the plate. The stress versus number of cycles to failure curve (S-N) obtained from the minimum mechanical properties of 3D-printed Ti6AI4V alloy according to ASTM F3001-14 to predict the fatigue limit. The comparison between experimental results and fatigue numerical predictions showed very good agreement. It was found that a linear elastic FE model was sufficient to estimate the fatigue limit, while an elastic-plastic model led to an accurate prediction throughout the implant’s cyclic life. The proposed method has great potential for enhancing patient-specific implant designs without the need for time-consuming and costly experimental regulatory testing.https://www.frontiersin.org/articles/10.3389/fbioe.2023.1133869/fullnumerical simulationfatigue analysisfinite element simulationbiomechanicsadditive manufacturingosteosynthesis plate |
| spellingShingle | Mohsen Nakhaei Manon Sterba Jean-Marc Foletti Jean-Marc Foletti Laurent Badih Michel Behr Experimental analysis and numerical fatigue life prediction of 3D-Printed osteosynthesis plates Frontiers in Bioengineering and Biotechnology numerical simulation fatigue analysis finite element simulation biomechanics additive manufacturing osteosynthesis plate |
| title | Experimental analysis and numerical fatigue life prediction of 3D-Printed osteosynthesis plates |
| title_full | Experimental analysis and numerical fatigue life prediction of 3D-Printed osteosynthesis plates |
| title_fullStr | Experimental analysis and numerical fatigue life prediction of 3D-Printed osteosynthesis plates |
| title_full_unstemmed | Experimental analysis and numerical fatigue life prediction of 3D-Printed osteosynthesis plates |
| title_short | Experimental analysis and numerical fatigue life prediction of 3D-Printed osteosynthesis plates |
| title_sort | experimental analysis and numerical fatigue life prediction of 3d printed osteosynthesis plates |
| topic | numerical simulation fatigue analysis finite element simulation biomechanics additive manufacturing osteosynthesis plate |
| url | https://www.frontiersin.org/articles/10.3389/fbioe.2023.1133869/full |
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