Additively Produced Ti-6Al-4V Osteosynthesis Devices Meet the Requirements for Tensile Strength and Fatigue

Alisdair R. MacLeod; Matthew Bishop; Alberto Casonato; Alborz Shokrani Chaharsooghi; Chris R. Bowen; H. S. Gill

doi:10.3390/jmmp9070227

Additively Produced Ti-6Al-4V Osteosynthesis Devices Meet the Requirements for Tensile Strength and Fatigue

Alisdair R. MacLeod, Matthew Bishop, Alberto Casonato, Alborz Shokrani Chaharsooghi, Chris R. Bowen, H. S. Gill

Orthoscape 3D Metal Printing

Research output: Contribution to journal › Article › peer-review

Abstract

The purpose of this study was to estimate the peak stresses in a laser powder bed fusion (LPBF) additive-manufactured (AM) osteosynthesis plate during physiological loading and establish if the mechanical properties of LPBF titanium alloy were suitable for this use case. Finite element models of subject-specific osteosynthesis plates for a cohort of 28 patients were created and used to calculate the peak maximum principal stresses during physiological loading, which was estimated to be 166 MPa twelve weeks post-operatively. All specimens were LPBF additively manufactured in Ti-6Al-4V alloy. ISO compliant tests were performed for tensile and fatigue, respectively. Fatigue testing was performed for specimens that had been heat-treated only and those that had been heat-treated and polished. The Upper Yield Stress was 1012.5 ± 19.2 MPa. The fatigue limit was 227 MPa for heat-treated only specimens and increased to 286 MPa for heat-treated and polished specimens. The finite element predicted stresses were below the experimentally established limits of yield and fatigue. The tensile and fatigue properties of heat-treated LPBF Ti-6Al-4V are therefore sufficient to meet the mechanical requirements of osteosynthesis plates. Polishing is recommended to improve fatigue resistance.

Original language	English
Article number	227
Journal	Journal of Manufacturing and Materials Processing
Volume	9
Issue number	7
Early online date	3 Jul 2025
DOIs	https://doi.org/10.3390/jmmp9070227
Publication status	Published - 31 Jul 2025

Data Availability Statement

The data presented in this study are available on request from the corresponding author due to delays in depositing data with Institutional repository.

Funding

The lead author was funded by Arthritis Research UK, grant 21495, and Versus Arthritis, grant 22262. Additional funding came from the SBRI Healthcare Programme Phase 2 award, grant 32619930. MB was funded by an Innovate KTP award. The funders played no role in the work performed and the preparation of the manuscript. The authors acknowledge the support of Orthoscape, 3D Metal Printing Ltd and Renishaw plc, who supplied components and specimens.

Funders	Funder number
3D Metal Printing Ltd
Renishaw
Arthritis Research UK	21495
Versus Arthritis	32619930, 22262

Keywords

additive manufacture
material properties
medical device
titanium alloy

ASJC Scopus subject areas

Mechanics of Materials
Mechanical Engineering
Industrial and Manufacturing Engineering

Access to Document

10.3390/jmmp9070227Licence: CC BY

Cite this

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abstract = "The purpose of this study was to estimate the peak stresses in a laser powder bed fusion (LPBF) additive-manufactured (AM) osteosynthesis plate during physiological loading and establish if the mechanical properties of LPBF titanium alloy were suitable for this use case. Finite element models of subject-specific osteosynthesis plates for a cohort of 28 patients were created and used to calculate the peak maximum principal stresses during physiological loading, which was estimated to be 166 MPa twelve weeks post-operatively. All specimens were LPBF additively manufactured in Ti-6Al-4V alloy. ISO compliant tests were performed for tensile and fatigue, respectively. Fatigue testing was performed for specimens that had been heat-treated only and those that had been heat-treated and polished. The Upper Yield Stress was 1012.5 ± 19.2 MPa. The fatigue limit was 227 MPa for heat-treated only specimens and increased to 286 MPa for heat-treated and polished specimens. The finite element predicted stresses were below the experimentally established limits of yield and fatigue. The tensile and fatigue properties of heat-treated LPBF Ti-6Al-4V are therefore sufficient to meet the mechanical requirements of osteosynthesis plates. Polishing is recommended to improve fatigue resistance.",

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AU - Bowen, Chris R.

AU - Gill, H. S.

PY - 2025/7/31

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N2 - The purpose of this study was to estimate the peak stresses in a laser powder bed fusion (LPBF) additive-manufactured (AM) osteosynthesis plate during physiological loading and establish if the mechanical properties of LPBF titanium alloy were suitable for this use case. Finite element models of subject-specific osteosynthesis plates for a cohort of 28 patients were created and used to calculate the peak maximum principal stresses during physiological loading, which was estimated to be 166 MPa twelve weeks post-operatively. All specimens were LPBF additively manufactured in Ti-6Al-4V alloy. ISO compliant tests were performed for tensile and fatigue, respectively. Fatigue testing was performed for specimens that had been heat-treated only and those that had been heat-treated and polished. The Upper Yield Stress was 1012.5 ± 19.2 MPa. The fatigue limit was 227 MPa for heat-treated only specimens and increased to 286 MPa for heat-treated and polished specimens. The finite element predicted stresses were below the experimentally established limits of yield and fatigue. The tensile and fatigue properties of heat-treated LPBF Ti-6Al-4V are therefore sufficient to meet the mechanical requirements of osteosynthesis plates. Polishing is recommended to improve fatigue resistance.

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Additively Produced Ti-6Al-4V Osteosynthesis Devices Meet the Requirements for Tensile Strength and Fatigue

Abstract

Data Availability Statement

Funding

Keywords

ASJC Scopus subject areas

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Additively Produced Ti-6Al-4V Osteosynthesis Devices Meet the Requirements for Tensile Strength and Fatigue

Abstract

Data Availability Statement

Funding

Keywords

ASJC Scopus subject areas

Access to Document

Other files and links

Fingerprint

Projects

ToKa - A Personalised Cost Effective Treatment for Knee Disease

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