This paper presents three methods of converting complex 3D models of STL type into solid models. For converting the STL models, specific approximation functions from CATIA and Creo Parametric software were used as well as 3D solid modeling methods that used sketches drawn for sections of the specific analyzed model. This conversion is required to get a solid 3D model that can be used for finite element analysis and to be processed using Boolean functions in specific CAD programs. This paper also presents a study of the effectiveness of FEA in respect to the time required for the analysis of each converted model. The analyzed STL files contain data obtained by computer tomography and are the 3D models of the human orthopedic system: the left zygomatic bone and upper part of the right femur. The presented conversion methods can be used by design engineers both in medical applications (where the complexity of forms is well known) for the design of implants and for industrial applications for reverse engineering.

This study was concerned with the adhesion of resin cement to metal surfaces obtained by selective laser melting process (SLM), and how it could be improved the bond strength at the biocomposite-metal junction. The SLM substrates were manufactured out of pure titanium (Ti), Ti₆Al₇Nb, and CoCr alloys. The metallic surfaces were covered with 5 types of biocomposites: 2 commercially resin-modified glass-ionomer cements (GC Fuji Plus and KETAC CEM) and 3 types of in-house developed materials. These biocomposites were mechanical characterized under compression and bending trials. The biocomposites-metal adhesion was settled both on as built metallic surfaces and after they were sandblasted with alumina. All the sandblasted SLM surfaces presented higher adhesion strength in comparison with the untreated specimens. The CoCr specimens show the highest bonding value. Additionally, the morphological aspects of joining interfaces were investigated using a scanning electron microscope (SEM). The mechanical properties and metal adhesion of these biocomposites were influenced by the liquid powder ratio. It is essential to apply a surface treatment on SLM substrate to achieve a stronger bond. Also, the chemical composition of biocomposite is a major factor which may improve the adhesion of it on different metallic substrates.

Polyethylene terephthalate (PET) recycling is one of the most important environmental issues, assuring a cleaner environment and reducing the carbon footprint of technological products, taking into account the quantities used year by year. The recycling possibilities depend on the quality of the collected material and on the targeted product. Current research aims to increase recycling quantities by putting together recycled PET in an innovative way as a filler for the additive manufactured metallic lattice structure. Starting from the structures mentioned above, a new range of composite materials was created: IPC (interpenetrating phase composites), materials with a complex architecture in which a solid phase, the reinforcement, is uniquely combined with the other phase, heated to the temperature of melting. The lattice structure was modeled by the intersection of two rings using Solid Works, which generates the lattice structure, which was further produced by an additive manufacturing technique from 316L stainless steel. The compressive strength shows low values for recycled PET, of about 26 MPa, while the stainless-steel lattice structure has about 47 MPa. Recycled PET molding into the lattice structure increases its compressive strength at 53 MPa. The Young’s moduli are influenced by the recycled PET reinforcement by an increase from about 1400 MPa for the bare lattice structure to about 1750 MPa for the reinforced structure. This sustains the idea that recycled PET improves the composite elastic behavior due to its superior Young’s modulus of about 1570 MPa, acting synergically with the stainless-steel lattice structure. The morphology was investigated with SEM microscopy, revealing the binding ability of recycled PET to the 316L surface, assuring a coherent composite. The failure was also investigated using SEM microscopy, revealing that the microstructural unevenness may act as a local tensor, which promotes the interfacial failure within local de-laminations that weakens the composite, which finally breaks.

This article provides a comprehensive, step-by-step framework that bridges the gap between the theory and engineering practical applications of Powder Bed Fusion (PBF) technology for producing high-quality metal parts suitable for end users. This proposed framework integrates multiple aspects into a coherent methodology on how to evaluate the PBF parameters and processing conditions, in order to establish a reliability scale for the PBF process on the Realizer 250 SLM machine. Experimental research, conducted over the past 10 years, reveals that the PBF process often encounters challenges related to process stability and part consistency. To address these issues, this paper introduces a novel method for evaluating the manufacturing process by considering the obtained physico-mechanical characteristics. The determined properties of PBF samples were ultimate tensile strength, Young’s modulus, the Poisson ratio, maximum elongation, hardness, and surface roughness. Test specimens were fabricated and tested without applying a stress relief heat treatment. Four bio-metal materials were studied as follows: pure Titanium, Ti6Al7Nb, CoCr, and CoCrWMo. Optimal processing parameters were established for each material focused on laser power, scanning speed, and hatch distance. To have a high chance of successfully printing, each material has its own set of PBF parameters. The results showed that the mechanical resistance can be up to 441 MPa for pure Ti (parameters 120 W, 500 mm/s, 0.12 mm) and 1159 MPa for CoCrWMo alloys (parameters 85 W, 500 mm/s, 0.10 mm). The mechanical properties of these materials are presented, offering valuable data for finite element analysis (FEA) necessary for designing medical implants. This paper provides practical guidelines beneficial for both medical application designers and manufacturers using PBF technology, contributing to enhanced reliability and efficiency in PBF-based metal part production.

This paper aims to investigate the “in vivo” behavior (over an extended period of time, namely six months) of hydroxyapatite and SiO2-TiO2 coating of Ti6Al7Nb alloy implants manufactured by selective laser melting. Innovative chemical implant coating by immersion technique was studied and the results were analyzed by optical and scanning electron microscopy (SEM). The results showed better osseointegration process for the coated implants and a much stabler biological behavior on the surface of the chemically treated implants.