Novel 3D coating of bioactive glass and metallic composites
Lead Research Organisation:
University of Sheffield
Department Name: Materials Science and Engineering
Abstract
The orthopaedic implant market is consistently projected to show strong growth, particularly in the joint reconstruction
sector. At a time where healthcare budgets are under severe pressure, there is a need for novel hip implants that deliver a
better quality of clinical outcome, but at the same or reduced cost. Implants are coated to aid implant bone-integration, and
the composition and structure of these coating is critical to the speed and strength of implant-bone integration and hence
the clinical outcome. The current coating is a combination of titanium (for strength) and bioactive glass (to facilitate bone
ingrowth), materials which have very different thermal properties and therefore must be laid down in two-stages if using a
conventional coating process. The ability to apply these materials by a novel 3D printing process, potentially in one-step,
will transform design and manufacture of orthopaedic implants. It will provide much greater design freedom to create new
functionally optimised material combinations and structures not achievable by a conventional process. This project
integrates the capabilities of SMEs operating end-to-end from design to product supply and the expertise of the University
of Sheffield in end-to-end simulation. Using a range of simulation methodologies developed by UoS in a series of
previously funded programmes (e.g. IMMPETUS EPSRC grants, EP/E063497 and EP/F023464), the Mercury Centre will
apply these to design and simulate the end-to-end manufacturing of the novel 3D coating of bioactive glass and metallic
composites. We will use phase field modelling to simulate the melting, fluid dynamics, solidification and phase
transformations during AM to optimise the process conditions for this application. We will use our unique combined finite
element/discrete element modelling to simulate the heat transfer, residual stresses and interaction between the metal and
bioglass. Multi-scale modelling will be used to link microstructure and properties throughout the manufacturing process.
This will extended to include the behaviour of the novel composite in vivo. It will deliver from design to supply a novel
additive manufacturing (AM) process to apply novel interpenetrating 3D glass and metallic composite coatings onto 3D
surfaces initially for orthopaedic (hip) implants. The coatings will enable design and manufacture of smaller (minimally
invasive) implants with 'large implant' performance having better mechanical stability and faster integration with bone thus
improving long-term clinical performance and a reduced revision rate. This delivers a significantly better clinical outcome
for patients and savings for the health service. The envisaged AM process has the potential to be faster and lower cost
than current two-stage deposition and to enable the manufacture (possibly in near-patient areas) of implants matched to
the patient using pre-operative bone scans. Transferability to other sectors will be demonstrated by the manufacture of a
solar diffuser material.
sector. At a time where healthcare budgets are under severe pressure, there is a need for novel hip implants that deliver a
better quality of clinical outcome, but at the same or reduced cost. Implants are coated to aid implant bone-integration, and
the composition and structure of these coating is critical to the speed and strength of implant-bone integration and hence
the clinical outcome. The current coating is a combination of titanium (for strength) and bioactive glass (to facilitate bone
ingrowth), materials which have very different thermal properties and therefore must be laid down in two-stages if using a
conventional coating process. The ability to apply these materials by a novel 3D printing process, potentially in one-step,
will transform design and manufacture of orthopaedic implants. It will provide much greater design freedom to create new
functionally optimised material combinations and structures not achievable by a conventional process. This project
integrates the capabilities of SMEs operating end-to-end from design to product supply and the expertise of the University
of Sheffield in end-to-end simulation. Using a range of simulation methodologies developed by UoS in a series of
previously funded programmes (e.g. IMMPETUS EPSRC grants, EP/E063497 and EP/F023464), the Mercury Centre will
apply these to design and simulate the end-to-end manufacturing of the novel 3D coating of bioactive glass and metallic
composites. We will use phase field modelling to simulate the melting, fluid dynamics, solidification and phase
transformations during AM to optimise the process conditions for this application. We will use our unique combined finite
element/discrete element modelling to simulate the heat transfer, residual stresses and interaction between the metal and
bioglass. Multi-scale modelling will be used to link microstructure and properties throughout the manufacturing process.
This will extended to include the behaviour of the novel composite in vivo. It will deliver from design to supply a novel
additive manufacturing (AM) process to apply novel interpenetrating 3D glass and metallic composite coatings onto 3D
surfaces initially for orthopaedic (hip) implants. The coatings will enable design and manufacture of smaller (minimally
invasive) implants with 'large implant' performance having better mechanical stability and faster integration with bone thus
improving long-term clinical performance and a reduced revision rate. This delivers a significantly better clinical outcome
for patients and savings for the health service. The envisaged AM process has the potential to be faster and lower cost
than current two-stage deposition and to enable the manufacture (possibly in near-patient areas) of implants matched to
the patient using pre-operative bone scans. Transferability to other sectors will be demonstrated by the manufacture of a
solar diffuser material.
Planned Impact
The orthopaedic implant market is consistently projected to show strong growth, particularly in the joint reconstruction
sector, with a total market size estimated at $36.7bn p.a.. At a time where healthcare budgets are under severe pressure,
there is a need for novel hip implants that deliver a better quality of clinical outcome, but at the same or reduced cost. This
project brings together partners with expertise in multiscale modelling, additive manufacturing, glass technology and orthopaedic implants. The aim is to develop the next generation of coatings for orthopaedic implants such as hip
replacements. The new combination glass and metal coatings will have better mechanical stability and faster integration
with bone thus improving long-term clinical performance and reducing the revision rate. This will deliver a significantly
better clinical outcome for patients and savings for the health service. The partners provide end-to-end supply chain, from
simulation and design, through manufacturing, through to the market place. The technology developed during this project
has the potential to transform the manufacture of orthopaedic implants and has applications in other fields requiring
specialist combinations of glass and metal.
sector, with a total market size estimated at $36.7bn p.a.. At a time where healthcare budgets are under severe pressure,
there is a need for novel hip implants that deliver a better quality of clinical outcome, but at the same or reduced cost. This
project brings together partners with expertise in multiscale modelling, additive manufacturing, glass technology and orthopaedic implants. The aim is to develop the next generation of coatings for orthopaedic implants such as hip
replacements. The new combination glass and metal coatings will have better mechanical stability and faster integration
with bone thus improving long-term clinical performance and reducing the revision rate. This will deliver a significantly
better clinical outcome for patients and savings for the health service. The partners provide end-to-end supply chain, from
simulation and design, through manufacturing, through to the market place. The technology developed during this project
has the potential to transform the manufacture of orthopaedic implants and has applications in other fields requiring
specialist combinations of glass and metal.
Publications
Bajda S
(2015)
Numerical analysis of highly reactive interfaces in processing of nanocrystallised multilayered metallic materials by using duplex technique
in Surface and Coatings Technology
Krzyzanowski M
(2016)
3D analysis of thermal and stress evolution during laser cladding of bioactive glass coatings.
in Journal of the mechanical behavior of biomedical materials
Krzyzanowski M
(2016)
Powder bed generation in integrated modelling of additive layer manufacturing of orthopaedic implants
in The International Journal of Advanced Manufacturing Technology
Nogiwa-Valdez AA
(2014)
Wear and degradation on retrieved zirconia femoral heads.
in Journal of the mechanical behavior of biomedical materials
Svyetlichnyy D
(2018)
Application of cellular automata and Lattice Boltzmann methods for modelling of additive layer manufacturing
in International Journal of Numerical Methods for Heat & Fluid Flow
Zeng P
(2015)
Characterisation of the oxide film on the taper interface from retrieved large diameter metal on polymer modular total hip replacements
in Tribology International
Zeng P
(2015)
Sub-surface characterisation of tribological contact zone of metal hip prostheses
in Journal of Physics: Conference Series
| Description | A new way of using additive layer manufacturing to produce a bioactive glass component for hip joint replacements has been developed. Models for the manufacturing process have been developed. |
| Exploitation Route | The results are being used by a number of companies to manufacture new components, which are currently undergoing clinical trials. This involves JRI (who make hip joint orthopaedics), Glass Technology International, who make the bioactive glass, and 3T, who are specialists in 3D printing. |
| Sectors | Manufacturing, including Industrial Biotechology |
| Description | A new manufacturing method for making acetabular cups with bioactive glass for hip joint replacements has been developed. The Sheffield part of the project produced a computer model that predicts the optimum process conditions for this application and explains the observed product output. In parallel, development of the process has been made through developing a bioactive glass powder, demonstrating that it can be 3D printed, defining the optimum process conditions and manufacturing a demonstrator component. |
| First Year Of Impact | 2018 |
| Sector | Manufacturing, including Industrial Biotechology |
| Impact Types | Economic |
| Description | JRI |
| Organisation | JRI Orthapaedics |
| Country | United Kingdom |
| Sector | Private |
| PI Contribution | Modelling the additive layer deposition of glass powders onto a metal substrate Understanding of the tribology of hip joints |
| Collaborator Contribution | Expert knowledge |
| Impact | Model to predict optimum process conditions for ALM |
| Start Year | 2014 |
| Title | Bioactive glass coating acetabular cup |
| Description | The product is being developed from a laboratory proof of concept to a product that can undergo clinical trials. |
| Type | Therapeutic Intervention - Surgery |
| Current Stage Of Development | Initial development |
| Year Development Stage Completed | 2016 |
| Development Status | Under active development/distribution |
| Impact | The acetabular cup will integrate with bone more rapidly and provide a superior joint that should allow for longer life in the patient. |