Effects of material morphology and processing conditions on the characteristics of hydroxyapatite and high-density polyethylene biocomposites by selective laser sintering

Hydroxyapatite (HA), a ceramic to which bone inherently bonds, incorporated into a polymer matrix enhances the bioactivity of implants. In order to rapid-manufacture bioactive implants, selective laser sintering (SLS) has been used to fabricate HA and high-density polyethylene (HDPE) composite (HA-HDPE). The properties of SLS-fabricated specimens have been investigated. The main aspects to be considered in the SLS technology are the properties of the materials used in the process and processing parameters (PPs). HA-HDPE composite specimens have been fabricated using five different powders with variations in particle size (PS), PS distribution, and five different laser PPs. The sintering height, the width, and the shrinkage of the specimens were determined and the effects of the particles and PPs on the physical properties were investigated. The HA-HDPE specimens were found to be highly porous and the sintered density and porosity of the specimens were influenced by the PS and PPs. The interparticle connectivity and the pore size range of the specimens were found to be predominantly determined by the PS and to a lesser extent also influenced by the PPs. The strength of these specimens and the relationship with porosity are discussed

Characterization and dynamic mechanical analysis of selective laser sintered hydroxyapatite filled polymeric composites

Selective laser sintering (SLS) is a manufacturing technique which enables the final product to be made directly and rapidly, without tooling or additional machining. For biomedical applications, SLS permits the fabrication of implants and scaffolds with complex geometry accurately and economically. In this study, hydroxyapatite-reinforced polyethylene and polyamide composites were fabricated using SLS. The SLS samples were characterized in terms of their internal structure, morphology, and porosity. The mechanical properties were examined by dynamic mechanical analysis. The effects of SLS processing conditions, including particle size and laser power, were investigated, and the results were compared with conventional compression-molded and machined specimens. The internal structure of sintered samples was porous, with open interconnected pores, and the pore size was up to 200 m. Particle size and laser energy play a key role in the final density and mechanical properties of the sintered components. In the parameter range used, the use of smaller particles produced higher density and stiffness, and the laser-induced energy could also be varied to optimize the manufacturing process. This study demonstrated that high-HA-content reinforced polymer composite can be successfully manufactured by SLS with controlled porosity features