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<p>Fracture is a concern in cranial implants constrained to a human skull due to the modulus mismatch of conventional implants and the human skull. This study introduces innovative metamaterial implants as an alternative to traditional implants. Laser power bed fusion technology is studied numerically, and it is a commonly used additive manufacturing process in implant applications. A sequentially coupled thermo-mechanical-metallurgical model is developed to demonstrate the effect of the cooling rate on the microstructure during the phase change process. Stress–strain, residual stress, and deflection analyses were performed, and the results were compared at successive reductive cooling rates. In-house FORTRAN Subroutines USDFLD and UEXPAN were utilized in the ABAQUS environment to analyze the formation of different phases in the heating and cooling cycles. The coupled thermo-mechanical crack growth behavior of Additively Manufactured cranial implants is presented using the Extended Finite Element Method (XFEM) numerical technique. Crack growth behavior was observed over a range of body temperatures. The fracture behavior of conventional implants was compared with that of innovative metamaterial cranial implants. It is observed that metamaterials are superior to traditional implants. The XFEM Model was validated with the phase-field model developed using the FORTRAN subroutine UEL and UMAT. The numerical results were compared with the experimental results. A good agreement was observed.</p>

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Fracture Behavior of Titanium Alloy Cranial Implants Additively Manufactured Using Laser Powder Bed Fusion Under Coupled Thermomechanical Loading

  • 期刊论文

  • 发表日期：

    2025年7月30日

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  • Altaf Ahmad Lone,
  • Nazir Ahmad Sheikh,
  • Mohammad Mursaleen Butt,
  • R. T. Durai Prabhakaran

摘要

Fracture is a concern in cranial implants constrained to a human skull due to the modulus mismatch of conventional implants and the human skull. This study introduces innovative metamaterial implants as an alternative to traditional implants. Laser power bed fusion technology is studied numerically, and it is a commonly used additive manufacturing process in implant applications. A sequentially coupled thermo-mechanical-metallurgical model is developed to demonstrate the effect of the cooling rate on the microstructure during the phase change process. Stress–strain, residual stress, and deflection analyses were performed, and the results were compared at successive reductive cooling rates. In-house FORTRAN Subroutines USDFLD and UEXPAN were utilized in the ABAQUS environment to analyze the formation of different phases in the heating and cooling cycles. The coupled thermo-mechanical crack growth behavior of Additively Manufactured cranial implants is presented using the Extended Finite Element Method (XFEM) numerical technique. Crack growth behavior was observed over a range of body temperatures. The fracture behavior of conventional implants was compared with that of innovative metamaterial cranial implants. It is observed that metamaterials are superior to traditional implants. The XFEM Model was validated with the phase-field model developed using the FORTRAN subroutine UEL and UMAT. The numerical results were compared with the experimental results. A good agreement was observed.