Structural Optimization of Lattice-Based Bone Implants for Improved Mechanical Properties

Abstract

Bone implants play a critical role in the field of medical science, enabling the restoration of damaged bone tissue. Traditional implants, however, often lack the ability to support bone regeneration, resulting in implant failure or the need for removal. To address this challenge, additive manufacturing (AM) has introduced innovative porous lattice structures capable of promoting osteointegration, a process crucial for implant success. This study focuses on optimizing lattice designs to balance porosity with mechanical strength, aiming to bridge the gap between implant requirements and performance. Three lattice types—Double Pyramid, Double Pyramid with Cross and Octahedral—were examined across varying porosity levels, setting the stage for a comprehensive analysis. Three primary objectives were established: 1) evaluated porosity and pore sizes for optimal osteointegration, 2) optimized lattice regions with maximum stress concentration, 3) Identified superior lattice types and configurations based on yield forces for enhanced strength and osseointegration. The results reveal that the Double Pyramid lattice exhibited superior performance, maintaining strength and stiffness within acceptable limits at 50% porosity. Double Pyramid with cross and Octahedral lattice structures displayed diminished mechanical properties beyond this threshold. The study's findings not only address implant requirements but also introduce a novel lattice variant that combines the benefits of enhanced strength and osteointegration at higher porosity levels. This research has significant implications for the medical field, additive manufacturing, aerospace industries, and applications involving high-strength lattice structures. The study's outcomes provide a valuable foundation for the development of tailored implants to meet specific patient needs, ultimately advancing the field of bone implantation.