Incorporating direct metal laser sintered complex shaped Ti-6Al-4V components in ultrasonic surgical devices

Cleary, R. , Li, X. and Lucas, M. (2021) Incorporating direct metal laser sintered complex shaped Ti-6Al-4V components in ultrasonic surgical devices. Journal of the Acoustical Society of America, 150(3), pp. 2163-2173. (doi: 10.1121/10.0006379) (PMID:34598605)

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Additive manufacturing (AM) offers opportunities to design more complex shapes of the Ti-6Al-4V parts commonly used in high-power ultrasonic surgical devices. Moreover, AM metal printing will be essential to the realization of miniature ultrasonic devices incorporating internal structures for minimally invasive surgical procedures. However, it is necessary first to verify the ultrasonic vibrational behavior of devices with three-dimensional (3D) printed metal parts. Therefore, two different prototype devices are fabricated, with CNC machined mill annealed and 3D printed Ti-6Al-4V parts. Both devices, an ultrasonic bone needle and a miniature ultrasonic scalpel, incorporate complex geometries but can be manufactured using subtractive processes so that the comparative effects of 3D printing on the vibrational performance of the devices can be elucidated. The metal microstructure is investigated through measurements of longitudinal and shear acoustic velocities and scanning electron microscopy. Comparisons of electrical impedance, frequency and modal responses, and the vibrational response at increasing levels of excitation enable evaluation of the efficacy of incorporating 3D printed Ti-6Al-4V parts. Results show that whereas the bone needle exhibited comparable vibrational responses for the measurement techniques used, the 3D printed bone cutting device exhibited a more dense modal response and developed cracks at high excitation levels.

Item Type:Articles
Additional Information:Acknowledgements: This work was supported by an EPSRC Programme Grant (Ultrasurge–Surgery enabled by Ultrasonics, EP/ R045291/1).
Glasgow Author(s) Enlighten ID:Cleary, Ms Rebecca and Li, Dr Xuan and Lucas, Professor Margaret
Authors: Cleary, R., Li, X., and Lucas, M.
College/School:College of Science and Engineering > School of Engineering > Systems Power and Energy
Journal Name:Journal of the Acoustical Society of America
Publisher:Acoustical Society of America
ISSN (Online):1520-8524
Published Online:27 September 2021
Copyright Holders:Copyright © The Author(s) 2021
First Published:First published in Journal of the Acoustical Society of America 150(3): 2163-2173
Publisher Policy:Reproduced under a Creative Commons licence

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Project CodeAward NoProject NamePrincipal InvestigatorFunder's NameFunder RefLead Dept
300671Surgery enabled by ultrasonicsMargaret LucasEngineering and Physical Sciences Research Council (EPSRC)EP/R045291/1ENG - Systems Power & Energy