Metalysis, England, has collaborated with TWI, also of England, to demonstrate the feasibility of its tantalum powder in metal additive layer manufacturing for biomedical applications such as patient-specific hip joints. Metal 3D-printed hip replacements could be a huge step forward, allowing patients to have a tailor-made joint by scanning their other hip and matching it with a metal 3D-printed replacement, rather than being restricted to the choice of standard sizes now available.
Metalysis’ high-quality metal powder, combined with TWI’s expertise, has demonstrated the significant potential of creating lattice structures via selective laser melting (SLM). The technology si suitable for hip joints, implants, and other new biomedical products that will benefit the patient and bring cost savings to the wider market.
The study successfully produced both uniform and randomized tantalum lattice structures that are bio-inert, replicate the structural stiffness of bone, and allow for extensive integration with bone cells, so that the new joint may be readily accepted by the body.
Metalysis has developed a process that produces metal powders directly from their respective oxides in just a single step, significantly lowering the environmental impact of its manufacture. The innovative process is not only cost-competitive, but also produces perfectly spherical metal powders of uniform size. As a result, the end products of metal additive manufacturing are structurally consistent with an improved as-built surface finish.
This study has shown that the durability and inertness of this highly versatile metal are retained through the production process. This is due to the quality of the powders, which allows the 3D printer to lay down the metal, forming a lattice structure with consistent strength and density.
Research specialist TWI has a history of bringing advances to the medical industry, and this study shows that Metalysis’ metals can be used to manufacture prototypes of the highest levels of quality by exploiting SLM additive manufacturing technology.
Metalysis is spearheading a revolution in the production of high-quality metals, including tantalum and titanium. Its patented process replaces the outdated, extremely expensive and highly toxic Kroll or Hunter process, which has been used for the past 70 years. Up until now, the inefficiency and expense of this process has made titanium and tantalum prohibitively expensive. Since the launch of its commercial plant in 2015, Metalysis has been supplying tantalum powder to its clients globally, working in collaboration with LPW Technology to serve its additive manufacturing customers.
