The use of elemental metallic powders and in situ alloying in additive manufacturing (AM) is of industrial relevance as it offers the required flexibility to tailor the batch powder composition. This solution has been applied to the AM manufacturing of nickel-titanium (NiTi) shape memory alloy components. In this work, we show that laser powder bed fusion (LPBF) can be used to create a Ni_55.7Ti_44.3 alloyed component, but that the chemical composition of the build has a large heterogeneity. To solve this problem three different annealing heat treatments were designed, and the resulting porosity, microstructural homogeneity, and phase formation was investigated. The heat treatments were found to improve the alloy’s chemical and phase homogeneity, but the brittle NiTi₂ phase was found to be stabilized by the 0.54 wt.% of oxygen present in all fabricated samples. As a consequence, a Ni₂Ti₄O phase was formed and was confirmed by transmission electron microscopy (TEM) observation. This study showed that pore formation in in situ alloyed NiTi can be controlled via heat treatment. Moreover, we have shown that the two-step heat treatment is a promising method to homogenise the chemical and phase composition of in situ alloyed NiTi powder fabricated by LPBF.

Nickel–titanium (NiTi) alloys have shown promise for a variety of biomedical applications because of their unique properties of shape memory, superelasticity, and low modulus of elasticity (Young's modulus). Nevertheless, NiTi bulk components cannot be easily machined (e.g., CNC, rolling, grinding, casting, or press molding) due to their thermomechanical sensitivity as well as inherent superelasticity and shape memory. Thus, powder bed fusion (PBF) additive manufacturing has been used to successfully fabricate NiTi medical devices that match the geometric and mechanical needs of a particular patient's condition. However, NiTi PBF fabrication leaves unmelted particles from the source powder adhered to external surfaces, which cause minor dimensional inaccuracy, increase the risk of mechanical failure, and once loose, may irritate or inflame surrounding tissues. Therefore, there is a need to develop a chemical polishing (cleaning) technique to remove unmelted powder from the surfaces of PBF-fabricated implants, especially from inner surfaces that are difficult to access with mechanical polishing tools. This technique is especially useful for highly porous devices printed at high resolution. In this study, a chemical polishing method utilizing HF/HNO ₃ solution was used to remove loosely attached (i.e., unmelted) powder particles from surfaces of porous, skeletal fixation plates manufactured by PBF AM. It was observed that 7 min of polishing in an HF/HNO ₃ solution comprising 7.5 HF: 50 HNO ₃ : 42.5 H ₂ O enabled successful removal of all relatively loose and unmelted powder particles. A microcomputed tomography study examination found that the volumetric accuracy of the polished skeletal fixation plates was ±10% compared with the computer-aided design (CAD) model from which it was rendered. This postprocessing chemical polishing protocol is also likely to be useful for removing loose powder, while maintaining CAD model accuracy and mechanical stability for other complexly shaped, porous, three-dimensional (3D), printed NiTi devices.

In this work, NiTi alloy parts were fabricated using laser powder bed fusion (LBPF) from pre-alloyed NiTi powder and in situ alloyed pure Ni and Ti powders. Comparative research on the corrosive and biological properties of both studied materials was performed. Electrochemical corrosion tests were carried out in phosphate buffered saline at 37 °C, and the degradation rate of the materials was described based on Ni ion release measurements. Cytotoxicity, bacterial growth, and adhesion to the surface of the fabricated coupons were evaluated using L929 cells and spherical Escherichia coli (E. coli) bacteria, respectively. The in situ alloyed NiTi parts exhibit slightly lower corrosion resistance in phosphate buffered saline solution than pre-alloyed NiTi. Moreover, the passive layer formed on in situ alloyed NiTi is weaker than the one formed on the NiTi fabricated from pre-alloyed NiTi powder. Furthermore, in situ alloyed NiTi and NiTi made from pre-alloyed powders have comparable cytotoxicity and biological properties. Overall, the research has shown that nitinol sintered using in situ alloyed pure Ni and Ti is potentially useful for biomedical applications.

Dental implants are, nowadays, established surgical devices for the restoration of lost teeth. Considered as an alternative for traditional prosthetic appliances, dental implants surpass them in reliability and patient feedback. Local drug delivery around the implants promotes osseointegration and reduces peri-implantitis. However, there are currently no methods of a multiple, precise topical administration of drugs to the implant area. Engineering coatings on the implants, drug application on carriers during implantation, or gingival pockets do not meet all requirements of dental surgeons. Therefore, there is a need to create porous implants and other medical devices that will allow a multiple drug delivery at a controlled dose and release profile without traumatic treatment. Due to the growing demand for the use of biologically active agents to support dental implant treatment at its various stages (implant placement, long-term use of dental superstructures, treatment of the peri-implant conditions) and due to the proven effectiveness of the topical application of pharmacological biologically active agents to the implant area, the authors would like to present a review and show the methods and devices that can be used by clinicians for local drug administration to facilitate dental implant treatment. Our review concludes that there is a need for research in the field of inventions such as new medical devices or implants with gradient solid–porous structures. These devices, in the future, will enable to perform repeatable, controllable, atraumatic, and repeatable injections of active factors that may affect the improvement of osteointegration and the longer survival of implants, as well as the treatment of peri-implantitis.