Multi-objective optimization of tibial tray geometry and cooling-induced properties using FEM for knee prosthesis applications

Purpose This study aims to enhance the safety and reliability of tibial tray designs used in total knee arthroplasty by analyzing the effects of region-specific cooling rates and geometric parameters on mechanical properties. Through an integrated experimental and computational approach, the study highlights the critical influence of thermal gradients during manufacturing. Design/methodology/approach The mechanical behavior of tibial tray materials was evaluated using hardness and tensile tests under varying cooling conditions. Finite Element Method (FEM) simulations were conducted to assess stress distribution and safety factors under physiological loading. Multi-objective optimization was performed using Response Surface Methodology (RSM) and Monte Carlo simulations to identify optimal geometric configurations. Findings Cooling rates were found to significantly affect mechanical properties, with hardness ranging from 320 to 597 HV and tensile strength between 390 and 616 MPa. FEM results showed maximum stress values of 3.18–6.14 MPa and average polyethylene safety factors of 6.4. Optimization via RSM revealed that material volume could be reduced from 9,387 mm3 to 3,754 mm3 through geometric refinement. Originality/value This research presents a novel combination of experimental and simulation-based methods—FEM, RSM, and Monte Carlo—to evaluate and optimize tibial tray design. Unlike prior studies, it quantitatively links cooling rate variations to mechanical performance and introduces a validated multi-objective framework that balances material efficiency with structural safety.