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Materials Science in Additive Manufacturing MAM for orthopedic bone plates: An overview

simultaneously introduce challenges related to quality focuses narrowly on specific parameters or aspects,
control and standardization. limiting broader applications [80,81,97-99] .
Post-processing techniques, while offering potential 6. The road ahead in additive manufactured
enhancements for AM bone plates, bring forth a series bone plates
of variables that necessitate rigorous oversight. Current
literature, while illuminating, underscores the need for more 6.1. Emerging biomaterials for orthopedics
nuanced research. The objective remains clear: optimizing Future advancements in orthopedic implants, especially
these processes, especially when the stakes involve critical bone plates, hinge on the expansion of suitable biomaterials
applications like bone plates where mechanical robustness tailored for AM. The current material palette for commercial
and biocompatibility are of paramount importance. metallic AM – comprising options such as stainless steel,
5. Navigating challenges in AM-based bone mild steel, and titanium alloy – is notably restricted. Even
plate creation among these, only a handful meet the stringent demands of
biomedical applications. Challenges with existing materials,
5.1. Material challenges such as the potential screw detachment or the release of
In AM for orthopedics, selecting the right materials is undesirable elements during prolonged use, underscore the
crucial but challenging. The limited availability of materials urgent need for innovative solutions.
specifically tailored for orthopedic applications like bone Machine learning (ML) emerges as a transformative
plates is a significant concern [60,95] . These materials need tool in this quest. By assisting in the discovery and
to balance critical properties, such as biocompatibility, optimization of nanobiomaterials, ML can significantly
mechanical strength, and controlled degradation rates, expedite the material development process. This data-
which are essential for successful orthopedic applications [7,68] . driven approach, as outlined by Suwardi et al. , offers
[27]
a streamlined methodology for biomaterial design
5.2. Design challenges optimization, harnessing ML’s capacity to analyze vast
Designing bone plates for AM involves computational and datasets and unveil intricate patterns. The ML-driven
clinical challenges. The complexity and computational biomaterial development typically encompasses three
intensity of topology optimization algorithms can hinder pivotal phases: (i) Analysis of synthesis, structure, and
their adoption . Moreover, the lack of long-term clinical properties; (ii) optimization of surface and interfaces;
[74]
data for AM-based bone plate designs raises questions and (iii) comprehensive material screening coupled with
about their clinical validity [36,38,75] . Practical design integrated manufacturing.
constraints, such as the number and positioning of screws,
also impact the flexibility and functionality of the final The merits of integrating ML into biomaterial
products . development are manifold, promising accelerated
[76]
development timelines, enhanced material performance,
5.3. Manufacturing challenges cost reductions, and heightened efficiency. In essence, by
leveraging ML, the future of orthopedics could witness the
The manufacturing process of AM bone plates faces several emergence of biodegradable materials that expertly balance
hurdles. High costs, particularly for techniques like PBF, mechanical robustness with controlled degradation rates,
are a primary concern . In addition, post-processing heralding a new era of safer, more effective bone plates.
[85]
steps essential for achieving desired product quality
are often time-consuming and complex [86,87,91] . Hybrid 6.2. Future design strategies for bone plates
manufacturing, which combines additive and subtractive
methods, introduces further complexities . The horizon of bone plate design, particularly within
[90]
the realm of AM, is being reshaped by the material-
5.4. Other challenges structure-performance integrated AM (MSPI-AM)
Beyond material, design, and manufacturing, there are concept. This integrated approach seeks to revolutionize
additional hurdles in AM-based bone plate creation. Many the AM landscape, prioritizing concurrent optimization of
advanced AM designs have not undergone comprehensive material selection, structural design, and manufacturing
biomedical testing, a critical step to ensure efficacy methodologies. Such an approach stands in stark contrast
and safety [34,77,78] . Patient-specific plates, while offering to the traditional “series mode” AM, which frequently
[100]
grapples with a time-intensive, trial-and-error process
.
customization, may lead to increased surgery costs and
duration, and necessitate specialized equipment and A particularly intriguing facet of MSPI-AM is its
expertise [36-38,79,96] . Moreover, research in this field often facilitation of parametric design. This enables agile
Volume 2 Issue 4 (2023) 10 https://doi.org/10.36922/msam.2113