Additive Manufacturing of Prostheses Using Forest-Based Composites

Bioengineering

Liselotte Hermansson¹  Martin Wallin¹  Kennet Hellberg²  Li Yang³  Göran Flodberg³  Henrik Pettersson³  Erik Stenvall⁴ 

[1] Department of Prosthetics and Orthotics, Faculty of Medicine and Health, Örebro University, 70185 Örebro, Sweden;Embreis AB, Tumstocksvägen 11 A, 18766 Täby, Sweden;RISE—Research Institutes of Sweden, Drottning Kristinas väg 61, 11486 Stockholm, Sweden;Stora Enso AB, Sommargatan 101A, 65009 Karlstad, Sweden;

关键词: biocomposite;    forest-based MFC;    fibrils;    additive manufacturing;    artificial limb;    fused deposition modeling (FDM);   

DOI  :  10.3390/bioengineering7030103

来源: DOAJ

【 摘 要 】

A custom-made prosthetic product is unique for each patient. Fossil-based thermoplastics are the dominant raw materials in both prosthetic and industrial applications; there is a general demand for reducing their use and replacing them with renewable, biobased materials. A transtibial prosthesis sets strict demands on mechanical strength, durability, reliability, etc., which depend on the biocomposite used and also the additive manufacturing (AM) process. The aim of this project was to develop systematic solutions for prosthetic products and services by combining biocomposites using forestry-based derivatives with AM techniques. Composite materials made of polypropylene (PP) reinforced with microfibrillated cellulose (MFC) were developed. The MFC contents (20, 30 and 40 wt%) were uniformly dispersed in the polymer PP matrix, and the MFC addition significantly enhanced the mechanical performance of the materials. With 30 wt% MFC, the tensile strength and Young´s modulus was about twice that of the PP when injection molding was performed. The composite material was successfully applied with an AM process, i.e., fused deposition modeling (FDM), and a transtibial prosthesis was created based on the end-user’s data. A clinical trial of the prosthesis was conducted with successful outcomes in terms of wearing experience, appearance (color), and acceptance towards the materials and the technique. Given the layer-by-layer nature of AM processes, structural and process optimizations are needed to maximize the reinforcement effects of MFC to eliminate variations in the binding area between adjacent layers and to improve the adhesion between layers.

【 授权许可】

Unknown