Contribution of the potential of additive manufacturing technologies to the performance of orthopedic implants

Additive manufacturing (AM) plays a crucial role in the medical field, particularly in the production of customized implants. Total knee arthroplasty (TKA) is widely used but has limitations, including stress shielding and loosening, exacerbated by patients’ daily activities. Integrating lattice structures into implants can help mitigate these issues by replicating human bone density.A finite element analysis was conducted on various lattice structures, including BCC, gyroid, octahedral, FCC, and BCCFCC, to assess their mechanical behavior. The surface-to-volume ratio (SVR) is a key factor in osseointegration, as a higher SVR enhances bone cell adhesion to porous implants. Among the analyzed structures, the H5e2 gyroid proved to be the most suitable, with an elastic limit of 120 MPa and a Young’s modulus of 55.220 GPa, closely matching human bone properties. Additionally, its SVR of 2.41 mm-1 promotes better osseointegration. These characteristics make the H5e2 gyroid a promising solution for knee implants, reducing the risk of complications and improving the long-term durability of the prosthesis.