Build Plate Surface Roughness for Implant Adhesion
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Solution Overview
Problem
Existing additive manufacturing techniques for forming medical devices, such as implants, often result in inadequate attachment strength between the additively manufactured structure and the build plate, which is a critical issue for implantable devices.
Innovation Solution
The approach involves optimizing the surface roughness of the build plate to match the morphology of the powder used, with a build plate having a plurality of peaks and indentations, and forming layers of powder structures that cover the peaks, thereby improving adhesion through thermal treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional additive manufacturing techniques are used to form medical devices, then the manufacturing process can be completed, but the attachment strength between the additively manufactured structure and the build plate is inadequate
Solution Approach 1:
The build plate surface is engineered with localized regions of varying roughness, including peaks and valleys, to create optimal mechanical interlocking zones. This local quality variation allows the powder structures to adhere more effectively to specific surface regions while maintaining overall structural integrity.
Solution Approach 2:
The build plate surface is pre-conditioned with a specific roughness profile before the additive manufacturing process begins. This preliminary surface preparation ensures that when powder structures are deposited and thermally treated, they achieve superior adhesion from the first layer, establishing a strong foundation for subsequent layers.
2Strength
If the surface roughness of the build plate is optimized to match powder morphology, then adhesion is improved, but the build plate manufacturing complexity increases
Solution Approach 1:
The build plate surface roughness parameters (amplitude, wavelength, distribution) are systematically varied to match the morphological characteristics of the powder particles. This parameter optimization creates a synergistic interface between the build plate and powder structures, maximizing adhesion through enhanced mechanical interlocking and surface contact area.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances the attachment strength between the additively manufactured structure and the build plate, ensuring a stronger and more reliable bond, which is crucial for implantable medical devices.
Implementation Method 1
the powder may be solidified by irradiating a layer of the powder with an energy source such as a laser or an electron beam
Implementation Method 2
The powder is fused, melted or sintered by the application of the energy source
Implementation Method 3
selective laser melting (SLM)
Implementation Method 4
The plurality of powdered structures may then be thermally treated, wherein the first layer covers the plurality of peaks
Data Source
AI summary
Medical devices, such as implants, and corresponding methods of manufacturing using an additive manufacturing technique, wherein the finished medical devices include a build plate retained therein, are disclosed. In some embodiments, the medical device includes a build plate having a plurality of peaks and a plurality of indentations, the plurality of peaks and the plurality of indentations together defining a surface roughness of an exterior surface of the build plate. The medical device may further include a first layer formed atop the exterior surface of the build plate, the first layer comprising a plurality of powder structures disposed over the plurality of peaks and the plurality of indentations. In some embodiments, an average peak distance between adjacent peaks of the plurality of peaks is less than an average width dimension of at least a portion of the plurality of powder structures.