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Additive manufacturing has revolutionized the creation of complex and intrinsic structures, offering tailored designs for enhanced product performance across various applications. Architected cellular or lattice structures exemplify this innovation, customizable for specific mechanical or functional requirements, boasting advantages such as reduced mass, heightened load-bearing capabilities, and superior energy absorption. Nonetheless, their single-use limitation arises from plastic deformation resulting from localized yield damage or plastic buckling. Incorporating NiTi shape memory alloys (SMAs) presents a solution, enabling structures to recover their original shape post-unloading. In this study, an NiTi architected metastructure, featuring auxetic behavior and a negative Poisson's ratio, was designed and fabricated via laser powder bed fusion (LPBF). The samples exhibit promising superelastic performance with recoverable deformation strains at room temperature. Comprehensive characterization processes evaluated the functional performance of the fabricated metastructures. The metastructure geometry promoted microstructure formation primarily along the wall thickness. Cycling compression tests, conducted at three applied force levels, demonstrated stable cyclic behavior with up to 3.8 % reversible deformation strain, devoid of plastic buckling or yielding damage. Furthermore, the NiTi metastructures displayed robust energy absorption capacity and damping behavior, underscoring their potential for reusable energy dissipators in various industries including aerospace, automotive, construction, and etc.

The present work explores the possibility of processing a CoCuFeMnNiTi0.13 high-entropy alloy by laser powder bed fusion (LPBF). The alloy, produced under optimised processing conditions, presents good densification but also hot cracks, caused by the liquation of an inter-dendritic Cu-rich phase. Microstructure of the as-built alloy is characterised by face centred cubic (FCC) columnar grains, containing Cu-poor dendrites and Cu-rich inter-dendritic areas. The alloy, which was designed to be strengthened by spinodal decomposition and precipitation, was subjected to different thermo-mechanical treatments to try and improve its properties. Direct ageing and solution treatment and ageing produced a strong but brittle material (tensile strength of 683 MPa and elongation to failure of 1.3%), whereas hot isostatic pressing followed by controlled cooling was able to heal pores and cracks while triggering the desired microstructural transformations (spinodal decomposition and precipitation). This resulted into a balanced set of mechanical properties (tensile strength of 473 MPa and elongation to failure of 7.6%). This work shows that proper post-processing can mitigate the issues typically affecting LPBF fabricated HEAs, producing tailored microstructures with satisfactory mechanical performances.

Since several years the need for realizing small and smart devices composed of functional materials is constantly increasing. Among this advanced materials, shape memory alloys (SMAs) are some of the most important functional materials in several applications, including in the biomedical and aerospace fields. Nowadays, laser cutting is probably the most widespread cutting technology for realising SMA mini- and micro-devices for several applications. The present manuscript reviews the scientific literature on the performance of laser-cut elements, in NiTi SMA, under different points of view. The literature was systematically analysed, according with a technological, metallurgical, functional and device/prototypal approaches. It can be highlighted that a relevant correlation between design, process condition and material performances can promote the realization of advanced smart devices made in NiTi SMA.

The present work aims at exploring the influence of laser welding on the functional behaviour of a Fe-20Mn-0.6C (wt.%) bioabsorbable alloy. At first, the selection of the most suitable process speed (40 mm/s) was done in order to obtain a full penetration joint with limited taper. Then, microstructural and mechanical analyses of welded sheets confirmed suitable performance of the joint, without porosity, thus preserving chemical composition, mechanical resistance and ductility even after welding. In particular, the base material comprised both γ austenite and ε martensite, while the welded samples showed a further type of martensite, namely α’. Moreover, ultimate tensile strength (1095 MPa and 1104 MPa in base and welded material, respectively) and elongation to failure (61.3% and 60.9%, respectively) were almost not influenced by the welding process. Considering the absorbable nature of these alloys, static immersion degradation tests were carried out, and confirmed that the surface of the welded bead did not exhibit a significant variation of the material degradation rate after 14 days in modified Hanks’ solution. Finally, a significant accumulation of degradation products, mainly (Fe,Mn)CO3, was observed along the joining line.

Laser powder bed fusion (LPBF) is the most widely used additive manufacturing technique and has received increasing attention owing to the high design freedom it offers. The production of aluminium alloys by LPBF has attracted considerable interest in several fields due to the low density of the produced alloys. The peculiar solidification conditions experienced by molten metal during the SLM process and its layer-by-layer nature causes a variety of microstructural peculiarities including the formation of metastable phases and supersaturated solid solutions, extreme microstructural refinement, and generation of residual stresses. Therefore, post-build heat treatments, which are commonly applied to conventionally produced aluminium alloys, may need to be modified in order to be adapted to the peculiar metallurgy of aluminium alloys manufactured using LPBF and address the specific issues resulting from the process itself. A number of studies have investigated this topic in recent years, proposing different approaches and dealing with various alloying systems. This paper reviews scientific research results in the field of heat treatment of selective laser melted aluminium alloys; it aims at providing a comprehensive understanding of the relationship between the induced microstructure and the resulting mechanical behaviour, as a function of the various treatment strategies.

The present work explores the possibility of employing the selective laser melting technique to produce parts in AlSi9Cu3 alloy. This alloy, currently prepared by high-pressure dye casting and intended for automotive application, may benefit from the refined microstructure commonly induced by additive manufacturing techniques. The process parameters were systematically varied to achieve full density, and the resulting defects were studied. Thereafter, microstructural features were analyzed, revealing that the high cooling rate, induced by the process, caused a large supersaturation of the aluminum matrix and the refinement of the eutectic structure. Again, the precipitation of the reinforcing θ phase provided numerous nucleation sites. These features were found to be related to the mechanical behavior of the SLMed AlSi9Cu3 alloy, which outperformed the conventional casted alloy in terms of elongation to failure and strain hardening rate both in the as-built and heat treated conditions.

Additively manufactured medical devices require proper surface finishing before their use to remove partially adhered particles and provide adequate surface roughness. The literature widely investigates regular lattice structures-mainly scaffolds with small pores to enhance osseointegration; however, only a few studies have addressed the impact of surface finishing on the dimensional deviation and the global and local mechanical responses of lattice samples. Therefore, the current research investigates the impact of biomedical surface finishing (i.e., corundum sandblasting and zirconia sandblasting) on Voronoi lattice structures produced by laser powder bed fusion (LPBF) with large pores and different thicknesses on the surface morphology and global and local mechanical behaviors. MicroCT and SEM are performed for the assessment of dimensional mismatch and surface evaluation. The mechanical properties are investigated with 2D digital image correlation (DIC) in quasi-static compression tests to estimate the impact of surface finishes on local maps of strain. In the quasi-static tests, both the global mechanical performances, as expected, and local 2D DIC strain maps were mainly affected by the strut thickness, and the impact of different surface finishings was irrelevant; on the contrary, different surface finishing processes led to differences in the dimensional deviation depending on the strut thickness. These results are relevant for designing lattice structures with thin struts that are integrated into medical prostheses that undergo AM.

Background and Objectives: Spring-assisted surgery is a popular option for the treatment of non-syndromic craniosynostosis. The main drawback of this procedure is the need for a second surgery for spring removal, which could be avoided if a distractor material could be metabolised over time. Iron-Manganese alloys (FeMn) have a good trade-off between degradation rate and strength; however, their biocompatibility is still debated. Materials and Methods: In this study, the neuro-compatibility of Fe-20Mn (wt.%) was assessed using standard assays. PC-12 cells were exposed to Fe-20Mn (wt.%) and stainless steel via indirect contact. To examine the cytotoxicity, a Cell Tox Green assay was carried out after 1, 2, and 3 days of incubation. Following differentiation, a neurite morphological examination after 1 and 7 days of incubation time was carried out. The degradation response in modified Hank's solution at 1, 3, and 7 days was investigated, too. Results: The cytotoxicity assay showed a higher toxicity of Fe-20Mn than stainless steel at earlier time points; however, at the latest time point, no differences were found. Neurite morphology was similar for cells exposed to Fe-20Mn and stainless steel. Conclusions: In conclusion, the Fe-20Mn alloy shows promising neuro-compatibility. Future studies will focus on in vivo studies to confirm the cellular response to Fe-20Mn.

Prosthetic reconstruction can serve as a feasible alternative, delivering both functional and aesthetic benefits to individuals with hand and finger injuries, frequent causes of emergency room visits. Implant-related infections pose significant challenges in arthroplasty and osteosynthesis procedures, contributing to surgical failures. As a potential solution to this challenge, this study developed a new class of silver (Ag)-doped chitosan (CS) coatings via electrophoretic deposition (EPD) on osseointegrated prostheses for infection therapy. These coatings were successfully applied to additively manufactured Ti 6 Al 4 V ELI samples. In the initial phase, the feasibility of the composite coating was assessed using the Thermogravimetric Analysis (TGA) and Attenuated Total Reflection (ATR) techniques. The optimized structures exhibited impressive water uptake in the range of 300-360%. Codeposition with an antibacterial agent proved effective, and scanning electron microscopy (SEM) was used to examine the coating morphology. Biologically, CS coatings demonstrated cytocompatibility when in direct contact with a fibroblast cell line (L929) after 72 h. When exposed to the Staphylococcus epidermidis strain (ATCC 12228), these coatings inhibited bacterial growth and biofilm formation within 24 h. These findings underscore the significant potential of this approach for various applications, including endoprostheses like hip implants, internal medical devices, and transcutaneous prostheses such as osseointegrated limb prosthetics for upper and lower extremities.

Background and Aims: Transcatheter aortic valve replacement (TAVR) is the mainstay of treatment of inoperable and severe high-risk aortic stenosis and is noninferior to surgical aortic valve replacement (SAVR) for low-risk and intermediate-risk patients as well. We aim to compare the valve size, area, and transaortic mean gradients in SAVR patients before and after the implementation of TAVR since being approved by the Food and Drug Administration  in 2011., Methods: Patients who underwent a bioprosthetic SAVR placement were divided into two groups based on the date of procedure: the early pre-TAVR implementation group (years 2011-2012) and the contemporary post-TAVR group (years 2019-2020). The primary endpoint was the mean gradient across the aortic valve within 16 months of surgery. The secondary endpoints included the difference in valve size and various aortic valve echocardiographic variables., Results: One hundred and thirty patients had their valves replaced in the years 2011-2012 and 134 in the years 2019-2020. The early group had a significantly higher mean gradient (median of 13 mmHg [interquartile range, IQR: 9.3-18] vs. 10 mmHg [IQR: 7.5-13.1], p  = 0.001) and a smaller median effective orifice area index (0.8 cm 2 /m 2 [IQR: 0.6-1] vs. 1.1 cm 2 /m 2 [IQR: 0.8-1.3], p  < 0.001). The median valve size was significantly smaller in the early group (median of 21 mm [IQR: 21-23] vs. 23 mm [IQR: 22.5-25], p  < 0.001)., Conclusion: In the contemporary era, surgical patients receive larger valves which translates into lower mean gradients, larger valve area, and lower rates of patient-prosthesis mismatch than in previous years before the routine introduction of TAVR., Competing Interests: The authors declare no conflicts of interest., (© 2022 The Authors. Health Science Reports published by Wiley Periodicals LLC.)

The present work explores the effect of a stress relieving heat treatment on the microstructure, tensile properties and residual stresses of the laser powder bed fused AlSi9Cu3 alloy. In fact, the rapid cooling rates together with subsequent heating/cooling cycles occurred during layer by layer additive manufacturing production make low temperature heat treatments desirable for promoting stress relaxation as well as limited grain growth: this combination can offer the opportunity of obtaining the best compromise between high strength, good elongation to failure and limited residual stresses. The microstructural features were analysed, revealing that the high cooling rate, induced by the process, caused a large supersaturation of the aluminum matrix and the refinement of the eutectic structure. Microhardness versus time curve, performed at 250 °C, allowed to identify a stabilization of the mechanical property at a duration of 25 h. The microstructure and the mechanical properties of the samples heat treated at 25 h and at 64 h, considered as a reference for the conventionally produced alloy, were compared with the ones of the as-built alloy. Finally, it was shown that a 59% reduction of the principal residual stresses could be achieved after the 25 h-long treatment and such evolution was correlated to the mechanical behaviour.