Researchers from Washington State University developed a groundbreaking surgical implant that eliminates 87% of staph infection-causing bacteria in laboratory tests while maintaining strength and compatibility with surrounding tissue like current implants.
Presented in the paper, titled "Additively manufactured Ti-Ta-Cu alloys for the next-generation load-bearing implants" published in the International Journal of Extreme Manufacturing, this innovation holds potential for improving infection control in widespread surgeries, such as hip and knee replacements, addressing a significant cause of implant failure.
3D-Printed Titanium Alloy Implant Fights Infections with Tantalum and Copper Enrichment
Titanium materials employed in surgical implants, such as those used in hip and knee replacements, were formulated more than half a century ago and present challenges in addressing infections. Despite proactive antibiotic treatment by surgeons, post-surgery infections can still arise, posing life-threatening complications.
In scenarios where infections take hold, necessitating revision surgery in approximately 7% of implant cases, the conventional procedure involves extracting the implant, cleaning the affected area, administering antibiotics, and inserting a new implant.
In a pioneering breakthrough, WSU researchers leveraged 3D printing technology to enhance the typical titanium alloy used in implants. They introduced 10% tantalum, a corrosion-resistant metal, and 3% copper into the material. Upon bacterial contact with the copper surface, their cell walls rupture, providing a robust antibacterial response.
Concurrently, tantalum fosters healthy cell growth in the adjacent bone and tissue, expediting the patient's recovery. The researchers conducted a thorough three-year study, assessing the implant's mechanical attributes, biological interactions, antibacterial effectiveness, and wear characteristics in laboratory and animal model settings.
Amit Bandyopadhyay, corresponding author and Boeing Distinguished Professor at WSU's School of Mechanical and Materials Engineering, also noted that the implant introduces inherent antibacterial properties through the material itself, offering a novel approach to combating infections.
Future Implications of Using the Enhanced Metal Implant
The study's co-author Susmita Bose, who holds the position of Westinghouse Distinguished Professor in the school, explained in a news release that the multifunctional device created through this research stands out for its ability to serve both infection control and optimal bone tissue integration.
Given the prevalent challenges of infections in today's surgical landscape, the potential of a device that addresses both aspects is considered highly valuable.
This research holds promise for enhancing infection management in various routine surgeries conducted globally, encompassing procedures like knee and hip replacements. The objective is to achieve a bacterial death rate exceeding 99% without compromising the integration of the device with the surrounding tissue.
Furthermore, the scientists aim to validate the materials' performance under real-world loading conditions that patients might encounter, ensuring their suitability for activities like hiking post-knee replacement surgery.
Continuing their work, the researchers are dedicated to refining the bacterial death rate to exceed 99%, emphasizing the importance of maintaining optimal tissue integration.
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