Design and Fabrication of ZTA Prosthesis by Uni-axial Compression Mold

Despite several decades of research for new materials for articulating joints in orthopedic applications, the efforts to develop a patient-specific prototype of such biomaterial devices are rather limited. While addressing this aspect, the present work demonstrates an integrated manufacturing approach how to fabricate the hip prosthesis of zirconia toughened alumina femoral head and acetabular socket initiation with composition and process optimization, and designing of prototypes and fabricate by Uni-axial compression mold. In this process, response surface methodology (RSM) approach was used to analyze and design of the ZTA composition for the prosthesis. The optimized ZTA composition was further conducted microstructural; physical, mechanical and tribological properties analyzed and reported. The custom-made uni-axial compression steel-die mold was fabricated to produce high strength green compact of the femoral head/acetabular socket and sintered at respective temperature. The present innovate manufacture technique can be materialize to be a scalable and commercially feasible fabrication strategy to make bio-ceramics based femoral head and acetabular socket biomedical devices.