BIOMATERIAL PRESENTATION GROUP 2.pptx

Biomaterials HIT

1. NAMES: REG NUMBER Masuku JOSEPH H220504z SIKUMBA DARLENE H220361X majoni B Godfrey H220083g LUCY KLOPPERS H220285F PEDZAI PRAISE h22003C Course : BIOMATERIALS group : 2

2. Manufacturability of biomaterials

3. Introduction The manufacturability of biomaterials refers to the processes and considerations involved in producing materials that can effectively interact with biological systems for medical applications. The manufacturability of biomaterials is a critical aspect that influences the application of biomaterials in medical fields, particularly in prosthetics and tissue engineering.

4. Key Factors Influencing Manufacturability Material Properties: The mechanical properties, chemical composition, and microstructure of biomaterials significantly affect their manufacturability. For instance, the use of functionally graded porous structures (FGPSs) in β-Ti21S alloys enhances osseointegration ( process by which a prosthetic implant becomes securely integrated with the surrounding bone ) due to optimized pore sizes and lower stiffness, which are crucial for prosthetic application. Processing Techniques: Advanced manufacturing methods, such as additive manufacturing (AM), allow for personalized biomaterial devices. AM techniques, including laser-based and extrusion-based processes, facilitate the production of complex geometries with minimal waste. Fabrication Methods: Techniques like ink-jet printing and sintering are employed to create scaffolds with controlled porosity, essential for applications like bone substitutes. These methods ensure that the final product retains necessary structural integrity and biocompatibility. Material Origin: Biomaterials can be derived from natural sources (like collagen or chitosan) or synthesized in laboratories (such as polymers and ceramics). The choice of origin affects the material's properties and its compatibility with biological tissues.

5. Material Selection Types of Biomaterials: Biomaterials can be classified into natural and synthetic categories. Natural biomaterials often exhibit excellent biocompatibility and bioactivity, while synthetic biomaterials can be engineered for specific mechanical properties and degradation rates. The choice between these materials depends on the specific application and desired outcomes. Biocompatibility: One of the primary considerations in material selection is biocompatibility, which refers to the ability of a material to perform with an appropriate host response when implanted in the body. This includes minimizing immune rejection and ensuring that the material can integrate with surrounding tissues. Mechanical Properties: The mechanical properties of biomaterials, such as strength, elasticity, and wear resistance, are critical for their performance in load-bearing applications, such as orthopedic implants. Materials must be selected based on their ability to withstand physiological loads without failure. Degradability : For many applications, especially in tissue engineering, the ability of a biomaterial to degrade at a controlled rate is essential. This allows the material to be gradually replaced by natural tissue as healing occurs. Biodegradable polymers, for instance, are often used for temporary scaffolds in regenerative medicine.

6. Key processing techniques in manufacturability of biomaterials Additive Manufacturing (AM) Additive manufacturing, also known as 3D printing, allows for the creation of complex geometries and tailored microstructures in biomaterials. Different AM techniques like material extrusion and powder bed fusion can be used based on the specific biomaterial and application requirements. AM enables customization of both the design and properties of biomaterials, allowing for patient-specific solutions. Collagen Processing Collagen, a widely used biomaterial, undergoes a series of processing steps including mechanical, chemical and physical treatments to purify, reshape, stabilize and sterilize the material. Collagen can be processed into various forms like fibrils, scaffolds, membranes, microspheres, hydrogels, and sponges for specific applications. Key collagen processing methods include dissolution, self-assembly, cross-linking, and electrospinning to enhance functionality.

7. Surface Modification Surface modification of biomaterials is crucial for improving biocompatibility, cell adhesion and proliferation. Techniques like laser processing, chemical etching, and micro-patterning can be used to create desired surface topographies and chemistries. Other Techniques Injection molding, melt extrusion, and electrospinning are suitable for processing polymeric biomaterials. Porous structures can be obtained using foaming processes or particle-leaching techniques. Alloying, strain hardening, and annealing are common methods for processing metal biomaterials.

8. Metals Fabrication Processes

9. Metals Used in Biomedical Applications Titanium and Titanium Alloys: Properties: High strength-to-weight ratio, excellent biocompatibility, corrosion resistance. Applications: Dental implants, joint replacements, bone plates. Stainless Steel: Types: 316L (low carbon) is the most common due to its corrosion resistance. Applications: Surgical instruments, orthopedic screws, cardiovascular stents. Cobalt-Chromium Alloys: Properties: Superior wear resistance, strength, and corrosion resistance. Applications: Hip and knee implants, dental prosthetics

10. Fabrication Processes

11. Casting Process: Metal is melted in a furnace and poured into a mold that defines the final shape. The mold can be made of sand (sand casting) or metal (die casting). After cooling, the cast metal part is removed from the mold. Advantages: Capable of producing complex shapes in a single step. Suitable for mass production with consistent quality. Challenges : Potential for defects like porosity, which can compromise mechanical properties. Requires post-casting treatments like machining or surface finishing. Applications : Prosthetic components, large joint implants.

12. Forging Process : Metal is heated to a high temperature and then shaped by applying compressive forces through hammering or pressing. Can be done in a closed die (closed-die forging) or with open dies (open-die forging). Advantages: Produces parts with high mechanical strength and fatigue resistance. Grain structure is refined, enhancing toughness. Challenges: Requires significant force, leading to high energy consumption. Limited to simpler shapes compared to casting. Applications : Hip implants, screws, and nails for orthopedic surgeries

13. Machining Process : Removal of material from a metal workpiece to achieve the desired shape using tools like lathes, mills, and drills. CNC Machining: Computer-controlled machining allows for high precision and complex geometries. Advantages : High precision and surface finish. Capable of creating complex shapes with tight tolerances. Challenges: Material wastage due to the subtractive nature of the process. Tool wear, especially when machining hard materials like titanium. Applications : Custom implants, intricate surgical tools, spinal cages.

14. Surface Treatments for Metals Passivation : Process: Stainless steel is treated with an acid solution to remove free iron and form a thin, protective oxide layer. Purpose: Enhance corrosion resistance, especially in environments like the human body. Polishing: Process: Abrasive materials are used to smooth the surface of the metal. Purpose: Reduce surface roughness, which minimizes wear and improves aesthetics. Application: Polished surfaces are preferred for surgical instruments to reduce tissue damage.

15. Anodization (for Titanium): Process : Electrochemical treatment that increases the thickness of the natural oxide layer. Purpose : Improves wear resistance, corrosion resistance, and allows for color-coding of implants. Applications : Polished and passivated surfaces for surgical instruments, anodized titanium for dental implants.

16. Applications Orthopedic Implants: Example: Hip and knee replacements made from cobalt-chromium alloys, fabricated through casting and forging for strength and durability. Dental Implants: Example: Titanium dental implants, machined to high precision and anodized for enhanced biocompatibility. Cardiovascular Stents: Example: Stainless steel stents, fabricated through a combination of machining and surface treatments to ensure flexibility and corrosion resistance.

17. Conclusion Different fabrication techniques can be combined (e.g., forging followed by machining) to achieve the desired properties for biomedical applications. Importance of Quality Control: There is need for rigorous quality control at each stage to ensure the safety and effectiveness of medical devices.

18. POLYMER FABRICATION

19. POLYMER FABRICATION PROCESSES 1. Extrusion 2. Injection Molding 3. Blow Molding 4. Compression Molding 5. Rotational Molding 6. Thermoforming 7. 3D Printing ( Additive Manufacturing) 8. Casting 9. Calendaring 10. Foaming

20. THE PROCESSES

21. Extrusion Polymer pellets or granules are fed into a heated barrel. The polymer melts and is pushed through a shaped die by a screw mechanism. The extruded material is then cooled and solidified into continuous shapes like tubes, sheets, or films.

22. APPLICATIONS Catheters: Thin, flexible tubes used for medical procedures. Tubing: For intravenous (IV) lines and other fluid delivery systems.

23. INFECTION MOULDING Melting: Polymer pellets are melted in a heated barrel. Injection: The molten polymer is injected into a closed Mold under high pressure. Cooling and Ejection: The polymer cools and solidifies within the Mold, and the Mold is then opened to eject the finished part.

24. APPLICATIONS Syringes: Single-use injection devices. Implants: Such as dental implants and orthopaedic devices, including joint replacements. Injection Molding: Best for high-precision, complex parts in high volumes with minimal waste. Requires custom Molds. Extrusion: Ideal for continuous, simple shapes and flexible production volumes. Involves shaping through a die and often has more material waste compared to injection Molding.

25. 3D PRINTING AND PROCESSING Design: A 3D model is created using computer-aided design (CAD) software. Printing: The model is sliced into thin layers, and the 3D printer deposits polymer material layer by layer to build the object. Curing/Solidifying: Depending on the technology (e.g., FDM, SLA, SLS), the polymer layers are fused or cured to form a solid structure.

26. APPLICATIONS IN THE MEDICAL FIELD 1. Custom Implants: 3D printing is used to create patient-specific implants, such as orthopaedic or dental implants, tailored to individual anatomical needs. 2. Prosthetics: Customized limb prosthetics can be designed and printed to fit the unique requirements of the patient, improving comfort and functionality. 3. Surgical Guides: Custom surgical guides and templates can be printed to assist surgeons in planning and performing precise operations, such as bone cutting or tumour removal.

27. BOLD MOLDING A molten polymer tube (parison) is placed inside a mold. Air is blown into the tube, expanding it to form a hollow object. The polymer cools and solidifies.

28. MEDICAL APPLICATIONS IV Bags: Flexible, sterile containers for intravenous fluids. Ostomy Pouches: Pouches used for collecting waste from a surgically created opening in the body. Respiratory Masks: Hollow, flexible masks used in oxygen therapy.

29. Compression Molding The mold A pre-measured amount of polymer is placed into a heated Mold. The mold is closed, and pressure is applied to shape the polymer. The polymer is heated and solidifies into the final part. Medical Applications Orthopaedic Braces: Custom-shaped braces for supporting injured limbs. Silicone Implants: Breast implants or facial implants made from silicone rubber. Custom-Made Splints: Molded to fit specific patient needs.

30. CERAMIC FABRICATION

31. INTRODUCTION Ceramic Biomaterials : Inorganic, non-metallic materials used in medical applications, known for their hardness, biocompatibility, and resistance to wear. Applications : Bone grafts, dental implants, joint replacements, and coatings for surgical devices.

32. Key Properties of Ceramic Biomaterials Biocompatibility : Non-reactive with biological tissues, suitable for implants. Mechanical Strength : High compressive strength, ideal for load-bearing applications. Wear Resistance : Durable with a long lifespan in the body.

33. Ceramic Fabrication Processes 1. Powder Processing Overview Foundation of ceramic fabrication, involving the preparation of fine ceramic powders. Steps Synthesis : Production of ceramic powders through methods like sol-gel processing or chemical vapor synthesis. Milling : Reducing particle size and achieving uniformity. Blending : Mixing powders with additives to improve properties.

34. 2. Forming Techniques Options Pressing : Uniaxial Pressing : Compresses powder into a mold using a single axis. Isostatic Pressing : Applies pressure uniformly in all directions, enhancing density. Casting : Slip Casting : Uses a liquid slurry poured into Molds to shape ceramics. Tape Casting : Produces thin ceramic sheets, useful for layered structures. Extrusion : Forces material through a die to create continuous shapes, like tubes or rods.

35. 3. Sintering Overview High-temperature process that densifies and strengthens the ceramic material. Methods Conventional Sintering : Uses high heat to bond particles. Hot Isostatic Pressing (HIP) : Combines heat and isostatic pressure to eliminate porosity and increase strength. Microwave Sintering : Utilizes microwave energy for rapid heating and energy efficiency.

36. 4. Machining and Finishing Techniques Grinding and Polishing : Achieves the desired surface finish and precision. Laser Machining : Provides high precision for intricate designs. Coating Applications : Enhances surface properties through techniques like plasma spraying.

37. Applications in Medicine Orthopaedic Implants Joint Replacements : Ceramics like alumina and zirconia used for hip and knee components. Bone Grafts : Hydroxyapatite ceramics used for bone repair and regeneration. Dental Applications Crowns and Bridges : Zirconia ceramics for their aesthetic and mechanical properties. Orthodontic Brackets : Ceramic materials offer strength and visual appeal. Surgical Tools Scalpel Blades : Ceramic blades retain sharpness longer than metal counterparts. Instrument Coatings : Ceramic coatings increase durability and biocompatibility.

38. Conclusion Conclusion Ceramic biomaterials play a vital role in modern medicine due to their unique properties. Ongoing research and technological advancements continue to expand their applications and improve fabrication processes.

39. Shaping -( Additive manufacturing, matching and deposition)

40. introduction Biomaterials: Substances engineered to interact with biological systems for medical purposes. Importance of Shaping: Critical in creating implants, prosthetics, and tissue engineering scaffolds.

41. Additive Manufacturing Overview Also known as 3D printing. Constructs parts layer by layer from 3D model data. Techniques Stereolithography (SLA) Uses light to cure liquid resin into hardened plastic. High precision and smooth surface finish. Selective Laser Sintering (SLS) Uses a laser to fuse powdered material. Suitable for complex geometries and multiple materials. Fused Deposition Modelling (FDM) Extrudes thermoplastic filaments. Cost-effective and widely accessible.

42. Applications Customized implants and prosthetics. Tissue scaffolds with complex internal structures

43. Advantages High customization and complexity. Rapid prototyping and reduced material waste. Challenges Material limitations and mechanical properties. Surface finish and post-processing requirements.

44. Deposition Techniques Overview Layer-by-layer addition of material, often at the atomic or molecular level. Techniques Physical Vapor Deposition (PVD) Material vaporized in a vacuum and deposited on substrates. Hard coatings for implants. Chemical Vapor Deposition (CVD) Chemical reactions produce a solid material from gaseous precursors. Used for coatings and surface modifications.

45. Applications Surface coatings for wear-resistance. Bioactive coatings for improved integration.

46. Advantages Enhanced surface properties. Ability to coat complex shapes uniformly. Challenges High equipment cost. Process complexity and environmental considerations.

47. Conclusion Integration of Techniques : Combining methods can optimize biomaterial properties for specific applications. Future Directions : Research into new materials and hybrid techniques to overcome current limitations.

48. Joining Techniques in Biomaterials: Thermal and Mechanical Welding

49. Introduction Joining in Biomaterials : Essential for creating multi-component devices, implants, and structures in biomedical applications. Importance : Ensures structural integrity and functionality of medical devices and implants.

50. Overview of Joining Techniques 1. Thermal Welding Definition A process that utilizes heat to join materials by melting and fusing them together.

51. Types of Thermal Welding Laser Welding : Uses focused laser beams to melt and join materials. Advantages : High precision, minimal heat-affected zone, suitable for delicate biomaterials.

52. Ultrasonic Welding: Employs high-frequency ultrasonic vibrations to generate heat through friction. Applications : Often used for joining thermoplastics in medical device fabrication.

53. Resistance Welding : Applies electrical current to create heat at the joint interface. Common Uses : Suitable for joining metal components in implants.

54. Advantages of Thermal Welding Precision : Allows for targeted heating and minimal thermal distortion. Speed : Fast joining processes suitable for high-volume manufacturing. Versatility : Compatible with various biomaterials, including metals, polymers, and ceramics.

55. Challenges Heat Sensitivity : Risk of damaging heat-sensitive biomaterials. Material Compatibility : Requires careful selection of compatible materials.

56. Mechanical Welding Definition Joining techniques that use mechanical force to create connections between materials without melting them.

57. Types of Mechanical Welding Mechanical Fastening : Involves the use of screws, bolts, or rivets to join components. Applications : Common in assembling larger biomedical devices, such as orthopaedic implants.

58. Adhesive Bonding : Utilizes biocompatible adhesives to bond materials together. Advantages : Distributes stress over a larger area, suitable for fragile materials.

59. Friction Stir Welding : A solid-state joining process where a rotating tool generates frictional heat to join materials without melting. Applications : Increasingly used for joining metals in biomedical devices.

60. Advantages of Mechanical Welding No Heat Input : Minimizes thermal deformation and damage to heat-sensitive materials. Diverse Applications : Suitable for a wide range of materials and geometries. Challenges Joint Strength : May not achieve the same strength as thermal welding methods. Surface Preparation : Requires clean and well-prepared surfaces for effective bonding

61. Applications in Biomedical Engineering 1.Implant Fabrication Thermal Welding : Used for creating complex multi-material implants, such as combining metal and polymer components. Mechanical Bonding : Commonly used in orthopaedic implants where mechanical fasteners secure components together. 2. Medical Device Assembly Thermal Welding : Employed in the assembly of disposable medical devices, ensuring sterility and reliability. Adhesive Bonding : Utilized in assembling delicate components of devices like catheters and sensors.

62. 3. Tissue Engineering Scaffolds Mechanical Joining : Incorporates mechanical methods to combine scaffold components while maintaining the integrity of bioactive materials.

63. Conclusion Integration of Joining Techniques : Both thermal and mechanical welding play crucial roles in the fabrication and assembly of biomedical devices. Future Directions : Ongoing research into hybrid joining techniques and advanced materials will enhance the performance and reliability of biomedical applications.

64. SURFACE TREATMENTS

65. INTRODUCTION Surface treatments like polishing, etching, and surface modification play critical roles in optimizing the performance of biomaterials, particularly in enhancing their interaction with biological environments.

66.   DEFINITION BENEFITS MEDICAL APPLICATIONS POLISHING Its a mechanical process that smoothens surface of a material by removing surface irregularities and achieving a mirror-like finish. Purpose It reduces surface roughness, which is crucial for applications where low friction and minimal wear are necessary, such as in joint implants.   -Improved Biocompatibility -Enhanced Fatigue Resistance: Polished surfaces are less prone to micro-cracks, increasing the material's longevity in the body.   Metallic implants (e.g., titanium, stainless steel) and dental materials to ensure they have a smooth, wear-resistant surface.     ETCHING   Is a chemical or electrochemical process that selectively removes material from a surface, creating micro- or nanoscale textures. *Purpose*: It's used to create surface patterns or increase surface roughness, which can enhance the material's interactions with cells and tissues.     Improved Cell Adhesion Increased Surface Area   Etching is often applied to titanium implants to improve osseointegration (the direct bonding of bone to the implant). In dental implants, etched surfaces can enhance the adhesion of dental cement or coatings.

67.   DEFINITION BENEFITS MEDICAL APPLICATIONS SURFACE MODIFICATION It involves altering the chemical composition or structure of a material's surface to achieve specific properties, without changing the bulk material.   *Coating*: Applying a thin layer of bioactive material (e.g., hydroxyapatite, polymers) to improve biocompatibility or deliver therapeutic agents. *Plasma Treatment*: Exposing the surface to a plasma (ionized gas) to modify its chemical composition, often to increase wettability or functionalize the surface for further coatings.     Drug Delivery Antibacterial Coatings*: Silver nanoparticles or other antibacterial agents can be coated onto biomaterial surfaces to prevent infections. - *Bioactive Surfaces*: Modifying surfaces to promote tissue integration or prevent immune rejection, commonly used in stents, catheters, and orthopaedic implants.

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69. THANK YOU!!