Optimization Design and SLM Manufacturing of Porous Titanium Alloy Femoral Stem

In order to solve the loosening problem caused by stress shielding of femoral stem prostheses in clinical practice, an optimization design method of a personalized porous titanium alloy femoral stem is proposed. According to the stress characteristics of the femur, the porous unit cell structures (TO-C, TO-T, TO-B) under three different loads of compression, torsion, and bending were designed by topology optimization. The mechanical properties and permeability of different structures were studied. Combined with the porous structure optimization, a personalized radial gradient porous titanium alloy femoral stem was designed and manufactured by selective laser melting (SLM) technology. The results show that the TO-B structure has the best comprehensive performance among the three topologically optimized porous types, which is suitable for the porous filling structure of the femoral stem, and the SLM-formed porous femoral stem has good quality. The feasibility of the personalized design and manufacture of porous titanium alloy implants is verified, which can provide a theoretical basis for the optimal design of implants in different parts.