The ATILA research project, funded by the Spanish Ministry of Science and Innovation and the European Union, has reached an important milestone. A prototype of the 3D printing technology has been installed in Valencia, enabling the production of biomedical implants made from titanium alloys for the first time in Spain. The development is based on Direct Energy Deposition technology (DED-LB/M) with laser welding wire, provided by Meltio, a company from Linares.
DED-LB/M uses titanium wire instead of powder, which makes the process more efficient and environmentally friendly. Wire reduces material loss and minimizes contamination compared to powder. However, the high reactivity of titanium to oxygen remains a key challenge. During the melting process, titanium can absorb oxygen, which has a negative impact on the material properties. To prevent this, inert gas is used to reduce oxygen absorption during the layer formation process.
The consortium, consisting of AIDIMME, the Research Foundation of the University Hospital of Valencia and the University of Salamanca, has made important progress in 2024. Geometric and mechanical tests on Ti6Al4V samples have investigated the limits and possibilities of the technology. Results show that precise structures such as cylindrical elements with a minimum diameter of 3 mm and complex angles can be realized. At the same time, thermographic controls have been introduced to monitor the microstructure and chemical composition of the implants.
The next step involves the production and testing of implant prototypes such as shoulder cages and acetabular cups. In parallel, mechanical tests and in vivo studies are underway. This research could form the basis for more efficient and customizable implants that meet stringent medical standards. Meltio and the ATILA consortium are demonstrating how additive manufacturing can transform medicine through innovative use of materials and precision manufacturing.
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