Med-Tech Innovation 3D printing


real challenge, and often must involve the use of proper solvents and other cleaning methods such as ultrasonic cleaning and vacuum bake out cycles. The ALM process may also result in unfused powder particles, which may be loosely adhered to the part surface or deeply embedded within the porous structure. Blasting is moderately effective at removal of these unfused particles. Options for blasting ALM parts to remove these particles may involve blasting with the same metal powder from which the ALM product was created. It may also involve a more traditional blast media such as zirconia or alumina. On the outside surface of the part, where the blast media can reach, loose or unfused particles are dislodged and removed. Within porous structures, loose particles may remain. The inherent risk is that these unfused particles may become dislodged while in service and work their way out of the part and into the body, potentially into critical regions such as joints. Removal of unfused particles is an aspect of ALM that requires careful consideration and will necessitate further development of manufacturing best practices and methods of prevention to mitigate this risk. The other challenge with blasting product to remove these loosely adhered or unfused particles lies in removing any entrapped blast media. Figure 4 shows entrapped blast media and organic residue likely deposited onto the porous layer through contact with handling or packaging materials.


Figure 4: SEM images of ALM part surfaces with blast media (left) and organic residue (right) remaining in the porous layer


The importance of analysis Clearly, analysis of loose particulate and chemical residues, and evaluation of new process implementation and improvement of existing processes are critical in this area of cutting-edge technology. There is a wide range of analysis methods available to perform thorough cleanliness evaluations of parts and the validation of manufacturing processes. Typical cleanliness evaluations involve gravimetric analyses to determine quantities and characteristics of any loose particulate, as well as analysis of chemical residues and surface effects.


Kaitlyn Calaluca is a Metallurgical Engineer at Lucideon (formerly know as Ceram and M+P Labs) Queens Road, Penkhull, Stoke on Trent ST4 7LQ, UK, tel. +44 (0)1782 764 428, e-mail: enquiries@lucideon.com, www.lucideon.com


Transforming Biomaterials for Life™


Design a device that facilitates the repair, recovery and regeneration of the human body.


Secant Medical integrates advanced biomaterials with fabric forming technology to create biomedical structures that meet device-specific biomimetic and compliance needs.


Applications Cardiovascular General surgery Neurovascular Orthopedics Regenerative medicine


www.secantmedical.com.com 26 ¦ September/October 2014 www.med-techinnovation.com


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