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Numerical assessment of advanced porous tibia implant designs based on different cellular structures

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Abstract

The rise of additive manufacturing gave hope to the design of orthopedic implants with comparable performance to natural human bone. The current research provides a numerical evaluation of the mechanical performance of three different Ti6Al4V cellular tibia implant designs. The investigated structures are face-centered cubic with vertical Z strut (FCCZ), reentrant and rhombic dodecahedron. Porous structures were designed with a pore size of 800 µm for bone ingrowth which improves implant fixation and osseo-integration. Porous stems were found to increase stress on the bone surface under the tibia tray accompanied by reducing both shear stress at the stem–bone interface and stress at the stem tip. Finally, proof-of-concept porous models 3D printed using Phrozen Shuffle XL demonstrated the manufacturability. A scanning electron microscope was used to measure the average pore sizes and the average strut sizes of the cellular microstructure to verify conformance to design.

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Acknowledgements

The authors acknowledge the support of Egypt-Japan University of Science and Technology (E-JUST) for providing the software used in this research.

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Authors and Affiliations

  1. Department of Mechatronics Engineering, Pyramids Higher Institute of Engineering and Technology, Giza, Egypt

    Basma Eltlhawy

  2. Department of Production and Mechanical Design Engineering, Faculty of Engineering, Mansoura University, Mansoura, P.O. 35516, Egypt

    Noha Fouda, T. El-Midany & Ibrahim Eldesouky

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  1. Basma Eltlhawy
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  4. Ibrahim Eldesouky
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Correspondence to Ibrahim Eldesouky.

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Eltlhawy, B., Fouda, N., El-Midany, T. et al. Numerical assessment of advanced porous tibia implant designs based on different cellular structures. Prog Addit Manuf 8, 807–817 (2023). https://doi.org/10.1007/s40964-022-00358-8

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