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<p>Additive manufacturing (AM) is widely adopted in the medical device sector as it allows for the creation of complex and customized designs. Ti6Al4V, increasingly utilized in orthopedic implants, now constitutes about 68% of US FDA submissions for AM devices. However, AM techniques may contribute to significant mechanical property variability due to numerous fabrication parameters. Creating representative material models offers one method to account for the impact of material variability on device performance. AM Ti6Al4V tensile specimens were produced via laser beam powder bed fusion and heat treated from multiple vendors. Quasi-static mechanical tensile and chemical constituent measurements were acquired and compared between vendors. On average, the samples met ASTM standard allowable tensile property minimums. Variability in mechanical properties was pronounced, evidenced by the high ranges and standard deviations within and between vendors. Elastic modulus, yield strength, ultimate strength, elongation at break, and reduction area had a relative max-min range of 64.9, 30.8, 23.4, 90.4, and 68.5%, respectively. Using the mechanical response distribution from all vendor samples and finite element analysis to tune post-necking behavior, elastic and plastic material models ranging from 1 to 99 percentile were created which may assist in predicting performance variability in AM medical devices.</p>

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Static Variability and Proposed Plastic Material Models in Additively Manufactured Laser Powder Bed Fusion Ti6Al4V

  • 期刊论文

  • 发表日期：

    2026年3月13日

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  • Abigail Tetteh,
  • Jay Kadakia,
  • Matthew Schwerin,
  • Matthew Di Prima,
  • Daniel Porter

摘要

Additive manufacturing (AM) is widely adopted in the medical device sector as it allows for the creation of complex and customized designs. Ti6Al4V, increasingly utilized in orthopedic implants, now constitutes about 68% of US FDA submissions for AM devices. However, AM techniques may contribute to significant mechanical property variability due to numerous fabrication parameters. Creating representative material models offers one method to account for the impact of material variability on device performance. AM Ti6Al4V tensile specimens were produced via laser beam powder bed fusion and heat treated from multiple vendors. Quasi-static mechanical tensile and chemical constituent measurements were acquired and compared between vendors. On average, the samples met ASTM standard allowable tensile property minimums. Variability in mechanical properties was pronounced, evidenced by the high ranges and standard deviations within and between vendors. Elastic modulus, yield strength, ultimate strength, elongation at break, and reduction area had a relative max-min range of 64.9, 30.8, 23.4, 90.4, and 68.5%, respectively. Using the mechanical response distribution from all vendor samples and finite element analysis to tune post-necking behavior, elastic and plastic material models ranging from 1 to 99 percentile were created which may assist in predicting performance variability in AM medical devices.