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Progress in Additive Manufacturing

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01-11-2022 | Full Research Article

Numerical assessment of advanced porous tibia implant designs based on different cellular structures

Authors: Basma Eltlhawy, Noha Fouda, T. El-Midany, Ibrahim Eldesouky

Published in: Progress in Additive Manufacturing | Issue 5/2023

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Abstract

The rise of additive manufacturing gave hope to the design of orthopedic implants with comparable performance to natural human bone. The current research provides a numerical evaluation of the mechanical performance of three different Ti6Al4V cellular tibia implant designs. The investigated structures are face-centered cubic with vertical Z strut (FCCZ), reentrant and rhombic dodecahedron. Porous structures were designed with a pore size of 800 µm for bone ingrowth which improves implant fixation and osseo-integration. Porous stems were found to increase stress on the bone surface under the tibia tray accompanied by reducing both shear stress at the stem–bone interface and stress at the stem tip. Finally, proof-of-concept porous models 3D printed using Phrozen Shuffle XL demonstrated the manufacturability. A scanning electron microscope was used to measure the average pore sizes and the average strut sizes of the cellular microstructure to verify conformance to design.

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Title: Numerical assessment of advanced porous tibia implant designs based on different cellular structures
Authors: Basma Eltlhawy
Noha Fouda
T. El-Midany
Ibrahim Eldesouky
Publication date: 01-11-2022
Publisher: Springer International Publishing
Published in: Progress in Additive Manufacturing / Issue 5/2023
Print ISSN: 2363-9512
Electronic ISSN: 2363-9520
DOI: https://doi.org/10.1007/s40964-022-00358-8

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