Effect of Process Parameters on Porosity of Parts printed with Selective LaserMelting/Selective Laser Sintering for use as Medical Implants

Effect of Process Parameters on Porosity of Parts printed with Selective LaserMelting/Selective Laser Sintering for use as Medical Implants | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Short Report Effect of Process Parameters on Porosity of Parts printed with Selective LaserMelting/Selective Laser Sintering for use as Medical Implants Yashwanth Nanda Kumar This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-5423740/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract Additive Manufacturing has increasingly gained traction in the last couple of decades. From a mere prototyping tool (Rapid Prototyping RP), it has now extended to being utilized in main scale manufacturing (Rapid Manufacturing RM) and in its specific application in Medical implant production. Selective Laser Melting (Complete Melting)/Selective Laser Sintering (Partial Melting) which are interchangeably used throughout multiple literature articles along with the terminology Direct Laser Melting (DLM), employs the principle of fusing metal powders layer by layer (Fig. 1) using a laser source to produce highly dense functional parts that are of near net shape. Recent developments have also shown its capability to produce parts that are porous and hollow for certain orthopedic applications. There are several alloys that have been developed and applied as an implant in the past decade, ranging from Cobalt-Chromium for dental implants, Titanium base alloys, Implant Steel and Bioresorbable alloys. This review paper was written to focus on the Titanium based alloys, specifically, the Titanium Aluminum Vanadium (Ti6Al4V) alloy that is used more prominently. While porosity is seen as a defect in regular manufacturing, as evident by most of the literature that aim at reducing porosity in order to make parts with higher density and better mechanical properties. We look to exploit this information to produce parts that would support the need to make osseointegration more feasible as certain applications do require porous implants to avoid bone resorption (Wolff’s law) caused due to the stress shielding from dense implants [ 1 ]. We highlight briefly the different parameters that directly affect the porosity in a part and narrow down on the desired parameters from different research studies and their implications. It is shown in most of the research papers the following parameters were explored: Laser Power, Hatch Spacing, Scan Speed and Energy Density (which is a function of the previous 3). Among these, Laser power, Scan Speed and Energy Density is shown to have a profound effect on the porosity of the manufactured part compared to the other parameters. Selective laser sintering Medical devices Ortho application Full Text Additional Declarations The authors declare no competing interests. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-5423740","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Short Report","associatedPublications":[],"authors":[{"id":376147617,"identity":"bfa1d833-2a0b-40e7-8a64-d5244cacfd0a","order_by":0,"name":"Yashwanth Nanda Kumar","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAtElEQVRIiWNgGAWjYLACHoYEBn4wi40ULZINJGsxOECsFoPbzc8evKlJS9x8I8eA4UPZYSK03DlmbjjnWE7iNqAWxhnniNFyI8FMmoetAqgldwMzbxtRWtK/SfP8q0jcPAOo5S9xWnLMpHnbchI3SAC1MBKjRfJGTpnk3L404xln3n842HMunbAWvhvp2yTefEuW7W9PS3zwo8yasBaFA0icAzgUoQL5BqKUjYJRMApGwYgGAPIMQCkTzdzaAAAAAElFTkSuQmCC","orcid":"https://orcid.org/0000-0001-9070-5087","institution":"University of Washington","correspondingAuthor":true,"prefix":"","firstName":"Yashwanth","middleName":"Nanda","lastName":"Kumar","suffix":""}],"badges":[],"createdAt":"2024-11-10 00:04:15","currentVersionCode":1,"declarations":{"humanSubjects":false,"vertebrateSubjects":false,"conflictsOfInterestStatement":false,"humanSubjectEthicalGuidelines":false,"humanSubjectConsent":false,"humanSubjectClinicalTrial":false,"humanSubjectCaseReport":false,"vertebrateSubjectEthicalGuidelines":false},"doi":"10.21203/rs.3.rs-5423740/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-5423740/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":68786496,"identity":"f0fe9d20-f4bc-4b92-be5d-c1c7190cc519","added_by":"auto","created_at":"2024-11-12 04:09:21","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":673583,"visible":true,"origin":"","legend":"","description":"","filename":"TermPaperYashwanth1968031Porosity.pdf","url":"https://assets-eu.researchsquare.com/files/rs-5423740/v1_covered_75935f4e-a13f-477c-899e-dbd67d4235a8.pdf"}],"financialInterests":"The authors declare no competing interests.","formattedTitle":"\u003cp\u003e\u003cstrong\u003eEffect of Process Parameters on Porosity of Parts printed with Selective Laser\u003c/strong\u003e\u003c/p\u003e\u003cp\u003e\u003cstrong\u003eMelting/Selective Laser Sintering for use as Medical Implants\u003c/strong\u003e\u003c/p\u003e","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":true,"hideJournal":true,"highlight":"","institution":"University of Washington","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Selective laser sintering, Medical devices, Ortho application","lastPublishedDoi":"10.21203/rs.3.rs-5423740/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-5423740/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003e \u003cb\u003eAdditive Manufacturing has increasingly gained traction in the last couple of decades. From a mere prototyping tool (Rapid Prototyping RP), it has now extended to being utilized in main scale manufacturing (Rapid Manufacturing RM) and in its specific application in Medical implant production. Selective Laser Melting (Complete Melting)/Selective Laser Sintering (Partial Melting) which are interchangeably used throughout multiple literature articles along with the terminology Direct Laser Melting (DLM), employs the principle of fusing metal powders layer by layer (Fig.\u0026nbsp;1) using a laser source to produce highly dense functional parts that are of near net shape. Recent developments have also shown its capability to produce parts that are porous and hollow for certain orthopedic applications. There are several alloys that have been developed and applied as an implant in the past decade, ranging from Cobalt-Chromium for dental implants, Titanium base alloys, Implant Steel and Bioresorbable alloys. This review paper was written to focus on the Titanium based alloys, specifically, the Titanium Aluminum Vanadium (Ti6Al4V) alloy that is used more prominently. While porosity is seen as a defect in regular manufacturing, as evident by most of the literature that aim at reducing porosity in order to make parts with higher density and better mechanical properties. We look to exploit this information to produce parts that would support the need to make osseointegration more feasible as certain applications do require porous implants to avoid bone resorption (Wolff\u0026rsquo;s law) caused due to the stress shielding from dense implants\u003c/b\u003e[\u003cspan citationid=\"CR1\" class=\"CitationRef\"\u003e1\u003c/span\u003e]. \u003cb\u003eWe highlight briefly the different parameters that directly affect the porosity in a part and narrow down on the desired parameters from different research studies and their implications. It is shown in most of the research papers the following parameters were explored: Laser Power, Hatch Spacing, Scan Speed and Energy Density (which is a function of the previous 3). 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