Optimization and Performance Analysis of Controllable Irregular Porous Bone Implant Structures

Irregular implants designed using Voronoi tessellation exhibit a high degree of biomimicry with respect to human bone morphology and mechanical behavior. However, conventional irregular structures often suffer from limited controllability of seed point control and excessive randomness, resulting in poor reproducibility and localized mechanical defects. To address these issues, this study proposes a controllable irregular porous structure design method that incorporates Poisson disk sampling to homogenize seed-point distribution, thereby improving structural randomness and mechanical properties. The effects of design parameters on porous structures were systematically investigated, followed by finite element analysis (FEA) to evaluate their mechanical behavior. In addition, 3D-printed porous specimens were fabricated and subjected to compression tests, and the experimental results were compared with simulation predictions. The results demonstrate that irregular porous structures designed by this method exhibit more favorable stress distributions than traditional designs, reduce the elastic modulus, alleviate stress shielding, and satisfy the requirements for biomedical implants. These findings highlight the strong potential of controllable irregular porous structures for future applications in bone implant development.