Process development and sensor-supported process monitoring and control of laser additive manufactured implants with complex external geometries and internal structures

增材制造，特别是基于激光的粉末床融合技术，可以制造复杂的部件和小批量。因此，这种方法注定用于制造患者特定的植入物，可以通过有针对性地使用梯度晶格结构来局部分级其刚度。因此，SP-1的总体目标是可重复处理由Ti-6Al-4V制成的患者特异性植入物，具有可调节的分级孔隙度。为此，必须根据激光粉末床熔合工艺条件设计相应的力学性能、表面形貌、腐蚀和失效性能，并研究它们的影响和相互作用。为了局部调整刚度，生成了梯度TPMS晶格结构（三周期最小曲面），并对其几何参数进行了变化，检查并适应了有限元模拟（有限元）确定的载荷情况。此外，在SP-1中收集在线过程监测数据，目的是能够将熔池几何形状和过程排放与设定的过程参数、所得表面和微观结构以及所得组件特性相关联。为了研究表面形貌（如高粗糙度）和复杂的TPMS晶格结构对涂层过程和组织整合的影响，其他子项目提供了不同的样品。基于细胞和生物相容性研究的结果，迭代进一步发展表面形貌和晶格结构的挑战出现了。基于实验设计方法（Design of experiments, DoE）对实验进行了规划、实施和分析。通过这种方式，开发的经验模型可以显示相关性和相互作用，并且可以在将来用于为单个植入物选择合适的工艺设置。

Additive manufacturing, especially the laser-based powder bed fusion technique, enables the manufacturing of complex components and small batches. This method is therefore predestined for the manufacturing of patient-specific implants, which can be locally graded in their stiffness through the targeted use of graded lattice structures. The overall aim of SP-1 is therefore the reproducible processing of patient-specific implants made of Ti-6Al-4V with adjustable, graded porosity. For this purpose, the mechanical properties, surface topography, corrosion and failure properties must be designed accordingly via the process conditions of the laser-based powder bed fusion process and their influences and interactions must be investigated. To locally adjust the stiffness, graded TPMS lattice structures (triply periodic minimal surface) are generated and their geometric parameters are varied, examined and adapted to the load situations determined by FE simulations (finite elements). In addition, online process monitoring data is collected in SP-1 with the aim of being able to correlate the melt pool geometry and process emissions with the set process parameters, the resulting surface and microstructure and the resulting component properties. In order to investigate the influence of the surface topography (e.g. high roughness) and the complex TPMS lattice structures on the coating process and tissue integration, different samples are made available to the other sub-projects. Based on the results of the cyto- and biocompatibility studies, the challenge arises to iteratively further develop the surface topography and the lattice structure. The experiments are planned, carried out and analyzed based on the Design of Experiments approach (DoE). This way a developed empirical model can show correlations and interactions and can be used in the future to select suitable process settings for individual implants.