Mechanical behavior of TPMS-based scaffolds: a comparison between minimal surfaces and their lattice structures

Novel 3D printed TPMS scaffolds: microstructure, characteristics and applications in bone regeneration

Bone defect disease seriously endangers human health and affects beauty and function. In the past five years, the three dimension (3D) printed radially graded triply periodic minimal surface (TPMS) porous scaffold has become a new solution for repairing bone defects. This review discusses 3D printing technologies and applications for TPMS scaffolds. To this end, the microstructural effects of 3D printed TPMS scaffolds on bone regeneration were reviewed and the structural characteristics of TPMS, which can promote bone regeneration, were introduced. Finally, the challenges and prospects of using TPMS scaffolds to treat bone defects were presented. This review is expected to stimulate the interest of bone tissue engineers in radially graded TPMS scaffolds and provide a reliable solution for the clinical treatment of personalised bone defects.

A novel artificial vertebral implant with Gyroid porous structures for reducing the subsidence and mechanical failure rate after vertebral body replacement

BACKGROUND

Prosthesis subsidence and mechanical failure were considered significant threats after vertebral body replacement during the long-term follow-up. Therefore, improving and optimizing the structure of vertebral substitutes for exceptional performance has become a pivotal challenge in spinal reconstruction.

METHODS

The study aimed to develop a novel artificial vertebral implant (AVI) with triply periodic minimal surface Gyroid porous structures to enhance the safety and stability of prostheses. The biomechanical performance of AVIs under different loading conditions was analyzed using the finite element method. These implants were fabricated using selective laser melting technology and evaluated through static compression and subsidence experiments.

RESULTS

The results demonstrated that the peak stress in the Gyroid porous AVI was consistently lower than that in the traditional porous AVI under all loading conditions, with a maximum reduction of 73.4%. Additionally, it effectively reduced peak stress at the bone-implant interface of the vertebrae. Static compression experiments demonstrated that the Gyroid porous AVI was about 1.63 times to traditional porous AVI in terms of the maximum compression load, indicating that Gyroid porous AVI could meet the safety requirement. Furthermore, static subsidence experiments revealed that the subsidence tendency of Gyroid porous AVI in polyurethane foam (simulated cancellous bone) was approximately 15.7% lower than that of traditional porous AVI.

CONCLUSIONS

The Gyroid porous AVI exhibited higher compressive strength and lower subsidence tendency than the strut-based traditional porous AVI, indicating it may be a promising substitute for spinal reconstruction.

Deep Learning in Mechanical Metamaterials: From Prediction and Generation to Inverse Design

Mechanical metamaterials are meticulously designed structures with exceptional mechanical properties determined by their microstructures and constituent materials. Tailoring their material and geometric distribution unlocks the potential to achieve unprecedented bulk properties and functions. However, current mechanical metamaterial design considerably relies on experienced designers' inspiration through trial and error, while investigating their mechanical properties and responses entails time-consuming mechanical testing or computationally expensive simulations. Nevertheless, recent advancements in deep learning have revolutionized the design process of mechanical metamaterials, enabling property prediction and geometry generation without prior knowledge. Furthermore, deep generative models can transform conventional forward design into inverse design. Many recent studies on the implementation of deep learning in mechanical metamaterials are highly specialized, and their pros and cons may not be immediately evident. This critical review provides a comprehensive overview of the capabilities of deep learning in property prediction, geometry generation, and inverse design of mechanical metamaterials. Additionally, this review highlights the potential of leveraging deep learning to create universally applicable datasets, intelligently designed metamaterials, and material intelligence. This article is expected to be valuable not only to researchers working on mechanical metamaterials but also those in the field of materials informatics.

Triply Periodic Minimal Surface-Based Scaffolds for Bone Tissue Engineering: A Mechanical, In Vitro and In Vivo Study

Triply periodic minimal surfaces (TPMSs) are found to be promising microarchitectures for bone substitutes owing to their low weight and superior mechanical characteristics. However, existing studies on their application are incomplete because they focus solely on biomechanical or in vitro aspects. Hardly any in vivo studies where different TPMS microarchitectures are compared have been reported. Therefore, we produced hydroxyapatite-based scaffolds with three types of TPMS microarchitectures, namely Diamond, Gyroid, and Primitive, and compared them with an established Lattice microarchitecture by mechanical testing, 3D-cell culture, and in vivo implantation. Common to all four microarchitectures was the minimal constriction of a sphere of 0.8 mm in diameter, which earlier was found superior in Lattice microarchitectures. Scanning by μCT revealed the precision and reproducibility of our printing method. The mechanical analysis showed significantly higher compression strength for Gyroid and Diamond samples compared with Primitive and Lattice. After in vitro culture with human bone marrow stromal cells in control or osteogenic medium, no differences between these microarchitectures were observed. However, from the TPMS microarchitectures, Diamond- and Gyroid-based scaffolds showed the highest bone ingrowth and bone-to-implant contact in vivo. Therefore, Diamond and Gyroid designs appear to be the most promising TPMS-type microarchitectures for scaffolds produced for bone tissue engineering and regenerative medicine. Impact Statement Extensive bone defects require the application of bone grafts. To match the existing requirements, scaffolds based on triply periodic minimal surface (TPMS)-based microarchitectures could be used as bone substitutes. This work is dedicated to the investigation of mechanical and osteoconductive properties of TPMS-based scaffolds to determine the influencing factors on differences in their behavior and choose the most promising design to be used in bone tissue engineering.

Improving the Mechanical Properties of a Lattice Structure Composed of Struts with a Tri-Directional Elliptical Cylindrical Section via Selective Laser Melting

In recent years, lattice structures produced via additive manufacturing have been increasingly investigated for their unique mechanical properties and the flexible and diverse approaches available to design them. The design of a strut with variable cross-sections in a lattice structure is required to improve the mechanical properties. In this study, a lattice structure design method based on a strut cross-section composed of a mixture of three ellipses named a tri-directional elliptical cylindrical section (TEC) is proposed. The lattice structures were fabricated via the selective laser melting of 316L alloy. The finite element analysis results show that the TEC strut possessed the high mechanical properties of lattice structures. Compression experiments confirmed that the novel lattice structure with the TEC strut exhibited increases in the elastic modulus, compressive yield strength, and energy absorption capacity of 24.99%, 21.66%, and 20.50%, respectively, compared with the conventional lattice structure at an equal level of porosity.

Biomimetic scaffolds using triply periodic minimal surface-based porous structures for biomedical applications

The design of biomimetic porous scaffolds has been gaining attention in the biomedical sector lately. Shells, marine sponges, shark teeth, cancellous bone, sea urchin spine, and the armadillo armor structure are examples of biological systems that have already been studied to drive the design of innovative, porous, and multifunctional structures. Among these, triply periodic minimal surfaces (TPMSs) have attracted the attention of scientists for the fabrication of biomimetic porous scaffolds. The interest stems from their outstanding properties, which include mathematical controllable geometry features, highly interconnected porous architectures, high surface area to volume ratio, less stress concentration, tunable mechanical properties, and increased permeability. All these distinguishing features enable better cell adhesion, optimal integration to the surrounding tissue avoiding stress shieldings, a good permeability of fluid media and oxygen, and the possibility of vascularization. However, the sophisticated geometry of these TPMS-based structures has proven challenging to fabricate by conventional methods. The emergence of additive manufacturing (AM) and the enhanced manufacturing freedoms and flexibility it guarantees could solve some of the bottlenecks, thus leading to a surge of interest in designing and fabricating such structures in this field. Also, the feasibility of using AM technologies allows for obtaining size programmable TPMS printable in various materials, from polymers to metal alloys. Here, a comprehensive overview of 3D-printed TPMS porous structures is provided from a design for additive manufacturing (DfAM) and application perspective. First, design strategies, geometry design algorithms, and related topological optimization are introduced according to diverse requirements. Based on that, the performance control of TPMS and the pros and cons of the different AM processes for fabricating TPMS scaffolds are summarized. Lastly, practical applications of 3D-printed biomimetic TPMS porous structures for the biomedical field are presented to clarify the advantages and potential of such structures.

A novel method combining VAT photopolymerization and casting for the fabrication of biodegradable Zn-1Mg scaffolds with triply periodic minimal surface

Zinc alloy porous scaffolds are expected to be the next generation of degradable orthopedic implants attributed to their suitable degradation rate. However, a few studies have thoroughly investigated its applicable preparation method and functionality as an orthopedic implant. This study fabricated Zn-1Mg porous scaffolds with triply periodic minimal surface (TPMS) structure by a novel method combining VAT photopolymerization and casting. As-built porous scaffolds displayed fully connected pore structures with controllable topology. The manufacturability, mechanical properties, corrosion behaviors, biocompatibility, and antimicrobial performance of the bioscaffolds with pore sizes of 650 μm, 800 μm, and 1040 μm were investigated, and then compared and discussed with each other. In simulations, the mechanical behaviors of porous scaffolds exhibited the same tendency as the experiments. In addition, the mechanical properties of porous scaffolds as a function of degradation time were studied through a 90-day immersion experiment, which can provide a new option for analyzing the mechanical properties of porous scaffolds implanted in vivo. The G06 scaffold with lower pore size presented better mechanical properties before and after degradation compared with G10. The G06 scaffold with the pore size of 650 μm revealed good biocompatibility and antibacterial properties, which makes it possible to be one of the candidates for orthopedic implants.

Mechanical Characterisation and Numerical Modelling of TPMS-Based Gyroid and Diamond Ti6Al4V Scaffolds for Bone Implants: An Integrated Approach for Translational Consideration

Additive manufacturing has been used to develop a variety of scaffold designs for clinical and industrial applications. Mechanical properties (i.e., compression, tension, bending, and torsion response) of these scaffolds are significantly important for load-bearing orthopaedic implants. In this study, we designed and additively manufactured porous metallic biomaterials based on two different types of triply periodic minimal surface structures (i.e., gyroid and diamond) that mimic the mechanical properties of bone, such as porosity, stiffness, and strength. Physical and mechanical properties, including compressive, tensile, bending, and torsional stiffness and strength of the developed scaffolds, were then characterised experimentally and numerically using finite element method. Sheet thickness was constant at 300 μm, and the unit cell size was varied to generate different pore sizes and porosities. Gyroid scaffolds had a pore size in the range of 600-1200 μm and a porosity in the range of 54-72%, respectively. Corresponding values for the diamond were 900-1500 μm and 56-70%. Both structure types were validated experimentally, and a wide range of mechanical properties (including stiffness and yield strength) were predicted using the finite element method. The stiffness and strength of both structures are comparable to that of cortical bone, hence reducing the risks of scaffold failure. The results demonstrate that the developed scaffolds mimic the physical and mechanical properties of cortical bone and can be suitable for bone replacement and orthopaedic implants. However, an optimal design should be chosen based on specific performance requirements.

Development of an architecture-property model for triply periodic minimal surface structures and validation using material extrusion additive manufacturing with polyetheretherketone (PEEK)

Additively manufactured structures designed from triply periodic minimal surfaces (TPMSs) have been receiving attention for their potential uses in the medical, aerospace, and automobile industries. Understanding how these complex geometries can be designed to achieve particular architectural and mechanical properties is essential for tuning their function to certain applications. In this study, we created design tools for visualizing the interplay between TPMS design parameters and resulting architecture and aimed to validate a model of the relationship between structure architecture and Young's modulus. A custom MATLAB script was written to analyze structural properties for families of Schoen gyroid and Schwarz diamond structures, and a numerical homogenization scheme was performed to predict the effective Young's moduli of the structures based on their architecture. Our modeling methods were validated experimentally with polyetheretherketone (PEEK) structures created using material extrusion additive manufacturing. The architectural characteristics of the structures were determined using micro-computed tomography, and compression testing was performed to determine yield strength and Young's modulus. Two different initial build orientations were tested to determine the behavior both perpendicular and parallel to the layer deposition direction (referred to as z-direction and xy-direction, respectively). The z-direction Young's modulus ranged from 289.7 to 557.5 MPa and yield strength ranged from 10.12 to 20.3 MPa. For the xy-direction, Young's modulus ranged from 133.8 to 416.4 MPa and yield strength ranged from 3.8 to 12.2 MPa. For each initial build orientation, the mechanical properties were found to decrease with increasing porosity, and failure occurred due to both strut bending and interlayer debonding. The mechanical properties predicted by the modeling agreed with the values found for z-direction samples (difference 2-11%) but less so for xy-direction samples (difference 27-62%) due to weak interlayer bonding and print path irregularities. Ultimately, the findings presented here provide better understanding of the range of properties achievable for additive manufacturing of PEEK and encouraging results for a TPMS architecture-property model.

Application of Computational Method in Designing a Unit Cell of Bone Tissue Engineering Scaffold: A Review

The design of a scaffold of bone tissue engineering plays an important role in ensuring cell viability and cell growth. Therefore, it is a necessity to produce an ideal scaffold by predicting and simulating the properties of the scaffold. Hence, the computational method should be adopted since it has a huge potential to be used in the implementation of the scaffold of bone tissue engineering. To explore the field of computational method in the area of bone tissue engineering, this paper provides an overview of the usage of a computational method in designing a unit cell of bone tissue engineering scaffold. In order to design a unit cell of the scaffold, we discussed two categories of unit cells that can be used to design a feasible scaffold, which are non-parametric and parametric designs. These designs were later described and being categorised into multiple types according to their characteristics, such as circular structures and Triply Periodic Minimal Surface (TPMS) structures. The advantages and disadvantages of these designs were discussed. Moreover, this paper also represents some software that was used in simulating and designing the bone tissue scaffold. The challenges and future work recommendations had also been included in this paper.

Porous Scaffold Design for Additive Manufacturing in Orthopedics: A Review

With the increasing application of orthopedic scaffolds, a dramatically increasing number of requirements for scaffolds are precise. The porous structure has been a fundamental design in the bone tissue engineering or orthopedic clinics because of its low Young's modulus, high compressive strength, and abundant cell accommodation space. The porous structure manufactured by additive manufacturing (AM) technology has controllable pore size, pore shape, and porosity. The single unit can be designed and arrayed with AM, which brings controllable pore characteristics and mechanical properties. This paper presents the current status of porous designs in AM technology. The porous structures are stated from the cellular structure and the whole structure. In the aspect of the cellular structure, non-parametric design and parametric design are discussed here according to whether the algorithm generates the structure or not. The non-parametric design comprises the diamond, the body-centered cubic, and the polyhedral structure, etc. The Voronoi, the Triply Periodic Minimal Surface, and other parametric designs are mainly discussed in parametric design. In the discussion of cellular structures, we emphasize the design, and the resulting biomechanical and biological effects caused by designs. In the aspect of the whole structure, the recent experimental researches are reviewed on uniform design, layered gradient design, and layered gradient design based on topological optimization, etc. These parts are summarized because of the development of technology and the demand for mechanics or bone growth. Finally, the challenges faced by the porous designs and prospects of porous structure in orthopedics are proposed in this paper.