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The production process of personalized custom bone plates
Data collection: CTA scanning technology or MRI technology was used to perform stereoscopic imaging on the patient’s bone area to obtain three-dimensional data of the patient’s bone area.
Design and Optimization: Use computer-aided design to display the patient’s bone location, determine the shape and size of the bone plate, and the corresponding connection method. During the design process, micro-holes and depressions can be designed on the surface of the bone plate that comes into contact with the patient’s bone to enhance the performance of the bone plate. Meanwhile, topological optimization is carried out on the design. For instance, in the production of personalized bionic artificial laminae for the lumbar vertebrae, the arc-shaped epidural baffle, bionic spinous processes, and fixed titanium plates are transformed into porous and grid-like structures after topological optimization.
3D printing: Output personalized bone plate data and print the bone plate using a metal powder selective laser melting 3D printer. The alloy particles used have a diameter of 15 to 45μm and are spherical.
Post-processing
Vacuum heat treatment: Vacuum heat treatment is carried out on the bone plates obtained by 3D printing. On the one hand, adjust the matrix structure of the bone plate, eliminate the defects of 3D printing, and ensure the mechanical properties of the bone plate; On the other hand, the unmelted metal particles and bubbles on the surface of the bone plate are removed by vacuum to improve the surface quality of the bone plate. For instance, in the production of personalized titanium alloy tibial bone plates, the vacuum heat treatment process involves the first stage of heat treatment. After the bone plates are loaded into the furnace, vacuuming is carried out, with the vacuum degree in the vacuum heat treatment furnace not less than 10Pa. Then, nitrogen is filled in or nitrogen is filled during the heating process and negative pressure is maintained in the furnace. The temperature is raised from room temperature for 45-60 minutes to 630-670 ℃. Maintain the temperature for 45 to 60 minutes, increase the temperature for 30 to 40 minutes to 850 to 900℃, maintain the temperature for 6 to 8 hours, vacuum to remove nitrogen, and then cool the bone plate in vacuum air to 20 to 100℃. In the second stage of heat treatment, the temperature is raised from 20-100 ℃ for 35-45 minutes to 530-570 ℃, and then held for 4-6 hours. After the holding period, the bone plate is immediately quenched in vacuum air to room temperature.
Surface treatment: A titanium nitride film is formed on the surface of the bone plate to enhance the surface hardness and corrosion resistance of the bone plate, effectively reducing the infection rate.