This investigation presents the numerical development of a fully porous tibial knee implant that is suggested to alleviate the clinical problems associated with current prostheses that are fully solid. A scheme combining multiscale mechanics and topology optimization is proposed to handle the homogenized analysis and property tailoring of the porous architecture with the aim of reducing the stiffness mismatch between the implant and surrounding bone. The outcome of applying this scheme is a graded lattice microarchitecture that can potentially offer the implant an improved degree of load bearing capacity while reducing concurrently bone resorption and interface micromotion. Asymptotic Homogenization theory is used to characterize the mechanics of its building block, a tetrahedron based unit cell, and the Soderberg fatigue criterion to represent the implant fatigue resistance under multiaxial physiological loadings. The numerical results suggest that the overall amount of bone resorption around the graded porous tibial stem is 26% lower than that around a conventional, commercially available, fully dense titanium implant of identical shape and size. In addition, an improved interface micromotion is observed along the tibial stem, with values at the tip of the stem as low as 17µm during gait cycle and 22µm for deep bend compared to a fully dense implant. This decrease in micromotion compared to that of an identical solid implant made of titanium can reasonably be expected to alleviate post-operative end of stem pain suffered by some patients undergoing surgery at the present time.
Keywords: Bone resorption; End-of-stem pain; Multiscale mechanics; Porous biomaterial; Tibial knee implant; Topology optimization.
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