Design Optimization and Manufacturing of Bio-fixed tibial implants using 3D printing technology

Abstract

To obtain high performance (matching, mechanical properties, and biocompatibility) of personalized biomechanical fixation-type tibial implants, three-dimensional reconstruction was performed using a combination of reverse and positive methods. The implant design was optimized using a topological optimization method, the shape-optimized B-unit structure was filled, and the performance was evaluated for implants prepared by direct forming technology of Selective Laser Melting (3D Printing). The results show obviously reduced weight of the tibial implant, increased stress and displacement, yet with a more uniform distribution. The mechanical properties of the tibial implant were lower than those of the B-units, the weight was lighter, and the stress distribution was more uniform. The surface of the tibial implants prepared by SLM appeared clean and bright, the metal texture was good, the structure between the porous struts was clear, the surface had low powder adhesion, the lap joint was good, and no obvious warping deformation or forming defects were observed. The results of this study provide a foundation for the direct application of high performance personalized biofixation implants.

Keywords: Data processing; Parametric modeling; Selective laser melting; Shape optimization; Topology optimization.