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Biomedical implants require stiffnesses matching those of the surrounding bone to avoid stress shielding. Triply-periodic-minimal-surface (TPMS) structures have shown promising characteristics in preventing stress shielding; however, they are limited in allowing for anisotropic stiffness properties that are typically inherent in bone. This paper presents an approach to simplifying a TPMS structure so that common geometries can be used to approximate it. The wall thickness is varied until the desired functional and directional stiffnesses are determined through finite element modelling. Validation of the finite element models is provided through the compression testing of laser powder bed fusion (LPBF) produced specimens. The displacement response to compression testing is presented along with the final structure, which closely matches the stiffness of bone. This approach has the potential to increase implant longevity and improve the lives of implant recipients.

Deterioration assessment of materials is essential to the continued effective operation of critical components operating, at high temperatures and stresses, in thermal power plants. Within progressive inspection strategies, small punch creep testing (SPCT) presents an effective method for establishing the degree of creep exhaustion of in-service power engineering alloys on account of the small volume of material required (Ø8 mm × 0.5 mm discs). These tests make the application of complex strain fields, analogous to the strain field experienced by the service components, possible. In addition, this work explores the application of a noncontact digital image correlation (DIC) method to the full-field measurement of strains which is not possible through traditional extensometry. The accelerated SPCT tests were performed on 12 % Cr ex-service steels subjected to 600 °C. Experimental methodologies and challenges associated with ex situ DIC-SPCT are discussed including equipment and parameter selection, speckle pattern application, preforming requirements and loading method. It is shown that the developed DIC technique using a stereo microscope, airbrushed speckle patterns, sombrero-preformed discs and interrupted tests can be used to compare surface strain development in various aged forms of the ex-service steel. Such an approach is valuable to understanding strain development in small punch tests and to assist in the comparative damage assessment of ex-service power plant materials.

LaserCUSING® is a selective laser melting (SLM) process that is capable of manufacturing parts by melting powder with heat input from a laser beam. LaserCUSING demonstrates potential for producing the intricate geometries specifically required for biomedical implants and aerospace applications. One main limitation to this form of rapid prototyping is the lack of published studies on the material performance of the resulting material. Studies of the material’s performance are often complicated by dependence on several factors, including starting powder properties, laser parameters, and post-processing heat treatments. This study aims to investigate the mechanical properties of LaserCUSING-produced Ti-6Al-4V and its performance relative to the conventional wrought counterpart. A combination of conventional and LaserCUSING-tailored heat treatments is performed. The resulting microstructures are studied and linked to the properties obtained from hardness tests. The findings highlight that LaserCused Ti-6Al-4V is competitive with traditional materials, provided that optimal parameters are chosen and parts are subject to tailored post-processing. In the as-built condition, LaserCused Ti-6Al-4V displays superior strength and hardness as a result of a martensitic microstructure, and a poorer performance in ductility. However, the material performance can be improved using tailored heat treatments. Careful consideration must be given to suitable post-processing before application in critical components in the aerospace or biomedical industry can occur