Composite Powder for Selective Laser Sintering Implants
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing composite particles for selective laser sintering have poor flowability, leading to issues with surface quality, component density, shrinkage behavior, and thermal conductivity in implants, particularly in neuro, oral, and maxillofacial surgeries, and lack an efficient manufacturing process.
Innovation Solution
A composite powder with microstructured particles, where large polymer particles (10 μm to 10 mm) are combined with small calcium salt particles (0.01 mm to 1 mm), resulting in improved flowability and surface quality, and allowing for better dimensional stability and heat conduction, enabling efficient production of high-quality implants with enhanced mechanical and biocompatibility properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If composite particles with calcium carbonate are used for selective laser sintering, then the implant material properties are improved, but the flowability of the powder deteriorates
Solution Approach 1:
The composite powder is segmented into two distinct particle size fractions: a coarse fraction (50-200 μm) providing structural integrity and a fine fraction (10-50 μm) improving flowability and surface quality. This segmentation allows each fraction to contribute its advantageous properties to the overall powder performance.
Solution Approach 2:
Different regions of the powder bed receive different particle size compositions. The coarse fraction dominates in the bulk material providing mechanical strength, while the fine fraction concentrates at the surface and in interparticle spaces to enhance flowability and surface finish, creating local quality optimization.
2Reliability
If composite particles with calcium carbonate are used for selective laser sintering, then the implant material properties are improved, but the surface quality and component density deteriorate
Solution Approach 1:
The particle size parameters are precisely controlled within specific ranges: coarse fraction 50-200 μm and fine fraction 10-50 μm. This parameter optimization ensures proper packing density, uniform laser energy absorption, and complete sintering, thereby improving surface quality and component density while maintaining material properties.
3Reliability
If composite particles with calcium carbonate are used for selective laser sintering, then the implant material properties are improved, but the shrinkage behavior and dimensional stability deteriorate
Solution Approach 1:
The patent creates a composite powder system combining polymer particles (PLA, PLGA, or PCL) with calcium carbonate particles in specific size fractions. This composite structure leverages the complementary properties of both materials: the polymer provides structural framework while calcium carbonate enhances dimensional stability and reduces shrinkage during sintering.
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
The composite powder significantly improves the quality of implants by increasing melt flow, reducing defects, and enhancing component density, biocompatibility, and mechanical properties, while allowing for controlled resorption kinetics and adjustable mechanical properties, making them suitable for complex surgical applications.
Implementation Method 1
The implant is produced by selective laser sintering of a composition containing composite powder
Implementation Method 2
selective laser sintering (SLM) process
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
The invention relates to an implant comprising a composite powder having microstructured particles, obtained by a method in which large particles are joined to small particles, wherein the large particles have an average particle diameter in the range from 10 µm to 10 mm, the large particles comprise at least one polymer, the small particles are arranged on the surface of the large particles and/or distributed non-homogenously within the large particles, the small particles comprise a calcium salt, the small particles have an average particle size in the range from 0.01 µm to 1.0 mm, wherein the particles of the composite powder have an average particle size (d50) in the range from 10 µm to less than 200 µm, and the fine-grain proportion of the composite powder is less than 50% by volume. The subject of the invention is therefore further implants obtained by selective laser sintering of a composition comprising a composite powder, in particular as an implant for applications in the area of neuro-surgery, oral, jaw, face, neck and ear surgery, and in hand, foot, thorax, rib, and shoulder surgery.