Additive manufacturing in orthopaedics: Clinical implications

3D printed orthopedic prostheses for domestic and wild birds-case reports

Regardless of the species, birds are exposed to injuries that lead to amputation of part of the body structure and often euthanasia. Based on the need for new technologies that improve the quality of life of birds with locomotor problems, the present case reports aimed to describe the development of custom-made three-dimensional (3D) prostheses for domestic and wild birds that suffered amputation or malformation of the hind limb. Using the measurements of the bird, a digital model was created for 3D printing using fused deposition modeling technology (FDM) by the Brazilian company 3D Medicine. In this study we report the use of 3D prosthesis for the rehabilitation of three birds with locomotor disorders in Brazil, the animals adapted to the custom-made prosthesis with an improvement in quality of life, better distribution of body weight, locomotion, and landing. This study describes the development of 3D prostheses for birds in Brazil, the first report of this technology for these species, and the pioneering development of socket prostheses for small birds. 3D prostheses offer a high-efficiency solution to improve the quality of life of animals with amputations and malformations of the hind limbs. In addition, 3D technology provides valuable tools for veterinary medicine, developing custom-made models for the most different anatomical demands of animal patients.

3D visualization and printing: An "Anatomical Engineering" trend revealing underlying morphology via innovation and reconstruction towards future of veterinary anatomy

The amalgamation of veterinary anatomy, technology and innovation has led to development of latest technological advancement in the field of veterinary medicine, i.e., three-dimensional (3D) imaging and reconstruction. 3D visualization technique followed by 3D reconstruction has been proven to enhance non-destructive 3D visualization grossly or microscopically, e.g., skeletal muscle, smooth muscle, ligaments, cartilage, connective tissue, blood vessels, nerves, lymph nodes, and glands. The core aim of this manuscript is to document non-invasive 3D visualization methods being adopted currently in veterinary anatomy to reveal underlying morphology and to reconstruct them by 3D softwares followed by printing, its applications, current challenges, trends and future opportunities. 3D visualization methods such as MRI, CT scans and micro-CT scans are utilised in revealing volumetric data and underlying morphology at microscopic levels as well. This will pave a way to transform and re-invent the future of teaching in veterinary medicine, in clinical cases as well as in exploring wildlife anatomy. This review provides novel insights into 3D visualization and printing as it is the future of veterinary anatomy, thus making it spread to become the plethora of opportunities for whole veterinary science.

On the need of a scale-dependent material characterization to describe the mechanical behavior of 3D printed Ti6Al4V custom prostheses using finite element models

Additive manufacturing is widely used in the orthopaedic industry for the high freedom and flexibility in the design and production of personalized custom implants made of Ti6Al4V. Within this context, finite element modeling of 3D printed prostheses is a robust tool both to guide the design phase and to support clinical evaluations, possibly virtually describing the in-vivo behavior of the implant. Given realistic scenarios, a suitable description of the overall implant's mechanical behavior is unavoidable. Considering typical custom prostheses' designs (i.e. acetabular and hemipelvis implants), complex designs involving solid and/or trabeculated parts, and material distribution at different scales hinder a high-fidelity modeling of the prostheses. Moreover, uncertainties in the production and in the material characterization of small parts approaching the accuracy limit of the additive manufacturing technology still exist. While recent works suggest that the mechanical properties of thin 3D-printed parts may be peculiarly affected by specific processing parameters (i.e. powder grain size, printing orientation, samples' thickness) as compared to conventional Ti6Al4V alloy, the current numerical models make gross simplifications in describing the complex material behavior of each part at different scales. The present study focuses on two patient-specific acetabular and hemipelvis prostheses, with the aim of experimentally characterizing and numerically describing the dependency of the mechanical behavior of 3D printed parts on their peculiar scale, therefore, overcoming one major limitation of current numerical models. Coupling experimental activities with finite element analyses, the authors initially characterized 3D printed Ti6Al4V dog-bone samples at different scales, representative of the main material components of the investigated prostheses. Afterwards, the authors implemented the characterized material behaviors into finite element models to compare the implications of adopting scale-dependent vs. conventional scaleindependent approaches in predicting the experimental mechanical behavior of the prostheses in terms of their overall stiffness and the local strain distribution. The material characterization results highlighted the need for a scale-dependent reduction of the elastic modulus for thin samples compared to the conventional Ti6Al4V, which is fundamental to properly describe the overall stiffness and local strain distribution on the prostheses. The presented works demonstrate how an appropriate material characterization and a scale-dependent material description is needed to develop reliable FE models of 3D printed implants characterized by a complex material distribution at different scales.

Computational evaluation of psoas muscle influence on walking function following internal hemipelvectomy with reconstruction

An emerging option for internal hemipelvectomy surgery is custom prosthesis reconstruction. This option typically recapitulates the resected pelvic bony anatomy with the goal of maximizing post-surgery walking function while minimizing recovery time. However, the current custom prosthesis design process does not account for the patient's post-surgery prosthesis and bone loading patterns, nor can it predict how different surgical or rehabilitation decisions (e.g., retention or removal of the psoas muscle, strengthening the psoas) will affect prosthesis durability and post-surgery walking function. These factors may contribute to the high observed failure rate for custom pelvic prostheses, discouraging orthopedic oncologists from pursuing this valuable treatment option. One possibility for addressing this problem is to simulate the complex interaction between surgical and rehabilitation decisions, post-surgery walking function, and custom pelvic prosthesis design using patient-specific neuromusculoskeletal models. As a first step toward developing this capability, this study used a personalized neuromusculoskeletal model and direct collocation optimal control to predict the impact of ipsilateral psoas muscle strength on walking function following internal hemipelvectomy with custom prosthesis reconstruction. The influence of the psoas muscle was targeted since retention of this important muscle can be surgically demanding for certain tumors, requiring additional time in the operating room. The post-surgery walking predictions emulated the most common surgical scenario encountered at MD Anderson Cancer Center in Houston. Simulated post-surgery psoas strengths included 0% (removed), 50% (weakened), 100% (maintained), and 150% (strengthened) of the pre-surgery value. However, only the 100% and 150% cases successfully converged to a complete gait cycle. When post-surgery psoas strength was maintained, clinical gait features were predicted, including increased stance width, decreased stride length, and increased lumbar bending towards the operated side. Furthermore, when post-surgery psoas strength was increased, stance width and stride length returned to pre-surgery values. These results suggest that retention and strengthening of the psoas muscle on the operated side may be important for maximizing post-surgery walking function. If future studies can validate this computational approach using post-surgery experimental walking data, the approach may eventually influence surgical, rehabilitation, and custom prosthesis design decisions to meet the unique clinical needs of pelvic sarcoma patients.

Active Materials for 3D Printing in Small Animals: Current Modalities and Future Directions for Orthopedic Applications

The successful clinical application of bone tissue engineering requires customized implants based on the receiver's bone anatomy and defect characteristics. Three-dimensional (3D) printing in small animal orthopedics has recently emerged as a valuable approach in fabricating individualized implants for receiver-specific needs. In veterinary medicine, because of the wide range of dimensions and anatomical variances, receiver-specific diagnosis and therapy are even more critical. The ability to generate 3D anatomical models and customize orthopedic instruments, implants, and scaffolds are advantages of 3D printing in small animal orthopedics. Furthermore, this technology provides veterinary medicine with a powerful tool that improves performance, precision, and cost-effectiveness. Nonetheless, the individualized 3D-printed implants have benefited several complex orthopedic procedures in small animals, including joint replacement surgeries, critical size bone defects, tibial tuberosity advancement, patellar groove replacement, limb-sparing surgeries, and other complex orthopedic procedures. The main purpose of this review is to discuss the application of 3D printing in small animal orthopedics based on already published papers as well as the techniques and materials used to fabricate 3D-printed objects. Finally, the advantages, current limitations, and future directions of 3D printing in small animal orthopedics have been addressed.

Data related to architectural bone parameters and the relationship to Ti lattice design for powder bed fusion additive manufacturing

The data included in this article provides additional supporting information on our publication (McGregor et al. [1]) on the review of the natural lattice architecture in human bone and its implication towards titanium (Ti) lattice design for laser powder bed fusion and electron beam powder bed fusion. For this work, X-ray computed tomography was deployed to understand and visualize a Ti-6Al-4V lattice structure manufactured by laser powder bed fusion. This manuscript includes details about the manufacturing of the lattice structure using laser powder bed fusion and computed tomography methods used for analyzing the lattice structure. Additionally, a comprehensive literature review was conducted to understand how lattice parameters are controlled in additively manufactured Ti and Ti-alloy parts aimed at replacing or augmenting human bone. From this literature review, lattice design information was collected and is summarized in tabular form in this manuscript.

Heterogeneous material mapping methods for patient-specific finite element models of pelvic trabecular bone: A convergence study

Patient-specific finite element (FE) models of bone require the assignment of heterogeneous material properties extracted from the subject's computed tomography (CT) images. Though node-based (NB) and element-based (EB) material mapping methods (MMMs) have been proposed, the sensitivity and convergence of FE models to MMM for varying mesh sizes are not well understood. In this work, CT-derived and synthetic bone material data were used to evaluate the effect of MMM on results from FE analyses. Pelvic trabecular bone data was extracted from CT images of six subjects, while synthetic data were created to resemble trabecular bone properties. The numerical convergence of FE bone models using different MMMs were evaluated for strain energy, von-Mises stress, and strain. NB and EB MMMs both demonstrated good convergence regarding total strain energy, with the EB method having a slight edge over the NB. However, at the local level (e.g., maximum stress and strain), FE results were sensitive to the field type, MMM, and the FE mesh size. The EB method exhibited superior performance in finer meshes relative to the voxel size. The NB method converged better than did the EB method for coarser meshes. These findings may lead to higher-fidelity patient-specific FE bone models.