CN107280811A - 基于3d打印的金属骨小梁技术的骨界面处理方法 - Google Patents
基于3d打印的金属骨小梁技术的骨界面处理方法 Download PDFInfo
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Abstract
一种基于3D打印的金属骨小梁技术的骨界面处理方法,其特征在于在人工关节假体界面上制备孔隙直径在300‑600微米金属骨小梁微孔层,所述金属骨小梁微孔层由激光熔覆3D打印机直接在人工关节界面上打印制备,或所述金属骨小梁微孔层先由3D打印机打印出骨小梁薄片,再应用烧结工艺将其结合到预制好的人工关节假体骨界面上。与现有技术相比,本发明采用的激光熔覆技术是对现有人工关节表面处理技术的一项革命性突破,为3D打印技术在人工关节假体骨界面技术领域的应用打下了基础,现国内外尚无同类技术产品。
Description
技术领域
本发明属于人工关节假体制备技术领域,具体涉及一种基于3D打印的金属骨小梁技术的骨界面处理方法。
背景技术
众所周知,通过植入假体构件以替换自然骨关节的一部分或全部来修复由于疾病或伤害而受损的骨关节。例如,髋关节的外科手术重建可能需要在股骨端部处植入以利用假体支承头替换自然股骨头的股骨假体构件,以及在经绞扩的髋臼腔或自然髋臼内植入以接纳假体支承头的假体髋臼杯。
已知一定范围的用于将假体固定到骨表面上或骨腔内的不同固定技术。此外,这些固定技术可相结合地使用。通常,通过使用从假体延伸到骨中的螺钉、钉子、丝线或类似的紧固件固定假体来提供机械固定。还已知的是向假体表面提供涂层,该涂层在植入时与骨相接触,或者紧邻骨,其中该涂层选择为用以促进骨整合。骨整合是指活骨与假体表面之间的直接结构和功能连接。
骨整合可由机械保持产生,由此骨向内生长到假体、特别是金属假体的表面特征中而将假体固定在骨上,或者可由生物活性保持产生,由此植入物涂覆有生物活性材料,该生物活性材料刺激骨形成而引起植入物与骨长合的化学连结。
对于诸多普遍在可植入假体内使用的金属 ( 例如钛或钛合金 ) 而言,会发生机械固定引起的骨整合。通过在假体与骨相接触的表面上设置拓扑特征如通气孔、槽缝和凹窝能够促进骨整合。不存在假体的化学保持并且这种保持取决于假体的表面积。
通过处理假体的表面部分以增加其表面积,例如蚀刻该表面,可促进通过机械固定的骨整合。已知对金属基底涂覆多孔涂层使得骨向内生长到孔内而在假体与骨之间形成牢固连结。多孔涂层可由在它们的接触点连结在一起的金属材料的多个小的分散颗粒组成,以在涂层中限定多个连接的间隙孔。
申请公布号 CN 103221000 A申请公布日 2013.07.24公开了一种多孔金属层至金属基体的电阻焊接技术,用于通过将整形假体的多孔金属层(22)电阻焊接至整型假体的在下面的金属基体(20)上而制造整形假体(10)的设备(100)和方法。电阻焊接工艺包括引导电流经过多孔层和基体,所述电流作为热量散发以引起材料的、尤其是沿着多孔层与基体之间分界面的软化和 / 或热熔。软化的和 / 或热熔的的材料在多孔层与基体之间的接触点处经受冶金结合以将多孔层牢固地固定到基体上。
申请公布号CN 105105875 A申请公布日2015.12.02公开了一种具有内生长功能的仿生人工髋关节,在股骨柄外表面制备了生物活性的多孔涂层,所述生物活性涂层 (6)采用烧结法、化学镀、电镀、等离子喷涂方法或高能粒子束成型法在股骨柄 (5) 表面制备具有生物活性的多孔涂层 ;生物活性涂层 (6) 从基底由里往外喷涂材料成分呈梯度变化;生物活性涂层 (6) 材料采用羟基磷灰石纳米粉末、生物活性玻璃粉末和氧化钛纳米粉末形成的复合材料或钛或钛合金或钽,生物活性涂层 (6) 材料的粉末粒径为30-100nm,生物活性涂层(6)的厚度为50-200μm ;生物活性涂层(6)的孔隙率为10-85%。
从上述现有技术可以看出,目前人工关节骨界面处理技术应用分别是喷涂和烧结两种工艺,由于技术难题原因,一直没能把3D打印的金属骨小梁技术应用到人工关节的骨界面应用中。
发明内容
为解决现有技术存在的上述技术缺陷,本发明的目的在于提供一种基于3D打印的金属骨小梁技术的骨界面处理方法。
为实现上述目的,本发明采用的技术方案:该基于3D打印的金属骨小梁技术的骨界面处理方法,其特征在于在人工关节假体界面上制备孔隙直径在300-600微米金属骨小梁微孔层,所述金属骨小梁微孔层由激光熔覆3D打印机直接在人工关节界面上打印制备,或所述金属骨小梁微孔层先由3D打印机打印出骨小梁薄片,再应用烧结工艺将其结合到预制好的人工关节假体骨界面上。
所述人工关节假体采用铸造或锻造技术制备出假体毛胚,再通过数控机床雕铣定型,最后通过激光溶覆技术在假体表面打印出金属骨小梁微孔。
所述烧结工艺是先铸造或锻造出人工关节假体毛胚,再通过数控机床雕铣出有卡槽的假体,将预先打印好的钛合金金属骨小梁薄片钳入假体卡槽,放入烧结设备中抽真空,再经800度右高温烧结而成。
所述金属骨小梁微孔层厚度为2-5mm。
优选的,所述金属骨小梁微孔层厚度为2mm。
采用上述技术方案的有益效果:该基于3D打印的金属骨小梁技术的骨界面处理方法是在人工关节假体骨界面上制备350-550微米金属骨小梁微孔层,金属骨小梁微孔层厚度为3-5mm,其厚度远远大于现有的喷涂方法制备的金属骨小梁微孔层厚度,大量的动物试验和临床试验证实应用3D打印的金属骨小梁植入体,当孔隙直径在350-550微米时骨长入效果最好,诱导或促进成骨细胞内生长的生物型固定相结合,结合面厚度为整个骨小梁的厚度,结合强度大,以保证假体服役期间的稳定性。满足强度和细胞内生长的要求,关节植入后依然能够维持原有骨的生物力学特征,而且最大限度的保存骨量,避免出现“应力遮挡”和假体松动。从而使人工关节假体与周围骨组织“生长”成为一体,缩短了假体坚强固定的时间,降低了假体松动下沉的并发症,延长了人工关节的使用寿命。由3D打印的金属骨小梁技术直接在人工关节假体骨界面上打印,有利于骨长入,是目前世界上最先进的人工关节界面处理技术,彻底颠覆现有人工关节假体界面处理技术。所述人工关节假体由铸造或锻造方法制备的金属假体,其抗疲劳强度大,能够提高假体的承重能力。
与现有技术相比,本发明采用的激光熔覆技术是对现有人工关节表面处理技术的一项革命性突破,为3D打印技术在人工关节假体骨界面技术领域的应用打下了基础,现国内外尚无同类技术产品。
附图说明
下面结合附图对本发明的具体实施例作进一步详细的说明。
图1为由激光熔覆3D打印机直接在人工关节界面上打印金属骨小梁微孔层图。
图2为通过数控机床雕铣出有卡槽的假体图。
图3为烧结工艺将其结合到预制好的人工关节假体骨界面图。
具体实施方式
如图1、2、3所示,该基于3D打印的金属骨小梁技术的骨界面处理方法,采用3D打印技术制备各种异型的人工关节假体,在人工关节假体界面上制备孔隙直径在300-600微米金属骨小梁微孔层2,所述金属骨小梁微孔层2由3D打印机直接在人工关节界面1上打印制备,或所述金属骨小梁微孔层2先由3D打印机打印出骨小梁薄片,再应用烧结工艺将其结合到预制好的人工关节假体骨界面上,通过烧结层3将骨小梁薄片与人工关节假体骨界面连接为牢固的一个整体。所述3D打印机为激光熔覆设备。所述人工关节假体采用铸造或锻造技术制备出假体毛胚,再通过数控机床雕铣定型,最后通过激光溶覆技术在假体表面打印出金属骨小梁微孔。所述烧结工艺是先铸造或锻造出人工关节假体毛胚,再通过数控机床雕铣出有卡槽的假体,将预先打印好的钛合金金属骨小梁薄片钳入假体卡槽4,放入烧结设备中抽真空,再经800度右高温烧结而成。
所述金属骨小梁微孔层厚度为2-5mm。优选的,所述金属骨小梁微孔层厚度为2mm。
以上借助具体实施例对本发明做了进一步描述,但是应该理解的是,这里具体的描述,不应理解为对本发明的实质和范围的限定,本领域内的普通技术人员在阅读本说明书后对上述实施例做出的各种修改,都属于本发明所保护的范围。
Claims (5)
1.一种基于3D打印的金属骨小梁技术的骨界面处理方法,其特征在于在人工关节假体界面上制备孔隙直径在300-600微米金属骨小梁微孔层,所述金属骨小梁微孔层由激光熔覆3D打印机直接在人工关节界面上打印制备,或所述金属骨小梁微孔层先由3D打印机打印出骨小梁薄片,再应用烧结工艺将其结合到预制好的人工关节假体骨界面上。
2.如权利要求1所述的基于3D打印的金属骨小梁技术的骨界面处理方法,其特征在于:所述人工关节假体采用铸造或锻造技术制备出假体毛胚,再通过数控机床雕铣定型,最后通过激光溶覆技术在假体表面打印出金属骨小梁微孔。
3.如权利要求1所述的基于3D打印的金属骨小梁技术的骨界面处理方法,其特征在于:所述烧结工艺是先铸造或锻造出人工关节假体毛胚,再通过数控机床雕铣出有卡槽的假体,将预先打印好的钛合金金属骨小梁薄片钳入假体卡槽,放入烧结设备中抽真空,再经800度右高温烧结而成。
4.如权利要求1所述的基于3D打印的金属骨小梁技术的骨界面处理方法,其特征在于:所述金属骨小梁微孔层厚度为2-5mm。
5.如权利要求4所述的基于3D打印的金属骨小梁技术的骨界面处理方法,其特征在于:所述金属骨小梁微孔层厚度为2mm。
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