1. Technical principles-from exact modelling to sophisticated structural manufacture.
Metal 3D printing creates detailed three-dimensional shapes by melting metal powder one layer at a time with a powerful beam, using methods like selective laser melting (SLM) or electron beam melting (EBM). Its main benefits consist of:
Capability for customisation: Create 3D models to achieve millimetre-level alignment with remaining limb anatomical features based on patient CT/MRI data.
The team is capable of building porous gradient structures (porosity 60–85%), biomimetic joints, and other challenging structures that are difficult to create with conventional methods, including complex structure manufacturing.
Rapid manufacturing: It takes just 72 hours from scanning to delivery, 80% less than usual procedures.
2. Material innovation: groundbreaking in functionalization and biocompatibility.
Though its 110 GPa elastic modulus is far higher than that of bone (10-30 GPa), conventional titanium alloy (Ti6Al4V) offers outstanding corrosion resistance. A new generation of material systems is transcending this bottleneck:
Ti Ta (75 GPa) and Ti Nb (45 GPa) adjust the structure of the material using tantalum/niobium elements, which reduces stiffness to levels that are similar to bone.
Coating the surface of titanium alloy with hydroxyapatite (HA) or bioglass is intended to help soft tissues stick and bones grow together with it.
Intelligent materials: Shape memory alloys-like NiTi-restrain their preset shape under the effect of body temperature and dynamically adjust to changes in residual limb shape.
From static adaptation to dynamic response: design optimisation
Metal 3D-printed prosthesis design has advanced beyond form duplication to become a stage for functional biomimetics:
Create models of walking patterns using finite element analysis and design flexible joints (like the ankle joint that can move up and down about 15 °) to adjust to different movement situations;
Optimisation of pressure distribution: Build a topology optimisation structure to prevent skin pressure ulcers and lower the peak pressure at the residual limb interface by 40 percent.
Customising texture (such as biomimetric skin texture) and colour matching services helps to improve psychological acceptance by means of these elements.
https://www.china-3dprinting.com/metal-3d-printing/slm-3d-printing-process.html