The Promotion of Mechanical Properties by Bone Ingrowth in Additive-Manufactured Titanium Scaffolds

Advanced topology of triply periodic minimal surface structure for osteogenic improvement within orthopedic metallic screw

Metallic screws are one of the most common implants in orthopedics. However, the solid design of the screw has often resulted in stress shielding and postoperative loosening, substantially impacting its long-term fixation effect after surgery. Four additive manufacturing porous structures (Fischer-Koch S, Octet, Diamond, and Double Gyroid) are now introduced into the screw to fix those issues. Upon applying the four porous structures, elastic modulus in the screw decreased about 2∼15 times to reduce the occurrence of stress shielding, and bone regeneration effect on the screw surface increased about 1∼50 times to improve bone tissue regrowing. With more bone tissue regrowing on the inner surface of porous screw, a stiffer integration between screw and bone tissue will be achieved, which improves the long-term fixation of the screw tremendously. The biofunctions of the four topologies on osteogenesis have been fully explored, which provides an advanced topology optimization scheme for the screw utilized in orthopedic fixation.

Application of Artificial Intelligence at All Stages of Bone Tissue Engineering

The development of artificial intelligence (AI) has revolutionized medical care in recent years and plays a vital role in a number of areas, such as diagnostics and forecasting. In this review, we discuss the most promising areas of AI application to the field of bone tissue engineering and prosthetics, which can drastically benefit from AI-assisted optimization and patient personalization of implants and scaffolds in ways ranging from visualization and real-time monitoring to the implantation cases prediction, thereby leveraging the compromise between specific architecture decisions, material choice, and synthesis procedure. With the emphasized crucial role of accuracy and robustness of developed AI algorithms, especially in bone tissue engineering, it was shown that rigorous validation and testing, demanding large datasets and extensive clinical trials, are essential, and we discuss how through developing multidisciplinary cooperation among biology, chemistry with materials science, and AI, these challenges can be addressed.

Functionally graded stem optimizes the fixed and sliding surface coupling mechanism

Whether the optimization of fixed surface and sliding surface coupling mechanism is related to the hierarchical level of functionally graded porous stem is unknown. The functionally graded porous finite element stem models were constructed using tetrahedral microstructure with the porosities of 47-95%. The stress distribution for femoral bone gradually strengthened, the stress shielding was decreased along the increase of hierarchical levels of the stem after implantation. The coupling mechanism of fixed and sliding surfaces can be optimized by the functional gradient porous stem, the performance advantages become more prominent with the increase of hierarchical levels of the structure.

Ultrasonic bandgaps in viscoelastic 1D-periodic media: Mechanical modeling and experimental validation

Multi-material additive manufacturing is receiving increasing attention in the field of acoustics, in particular towards the design of micro-architectured periodic media used to achieve programmable ultrasonic responses. To unravel the effect of the material properties and spatial arrangement of the printed constituents, there is an unmet need in developing wave propagation models for prediction and optimization purposes. In this study, we propose to investigate the transmission of longitudinal ultrasound waves through 1D-periodic biphasic media, whose constituent materials are viscoelastic. To this end, Bloch-Floquet analysis is applied in the frame of viscoelasticity, with the aim of disentangling the relative contributions of viscoelasticity and periodicity on ultrasound signatures, such as dispersion, attenuation, and bandgaps localization. The impact of the finite size nature of these structures is then assessed by using a modeling approach based on the transfer matrix formalism. Finally, the modeling outcomes, i.e., frequency-dependent phase velocity and attenuation, are confronted with experiments conducted on 3D-printed samples, which exhibit a 1D periodicity at length-scales of a few hundreds of micrometers. Altogether, the obtained results shed light on the modeling characteristics to be considered when predicting the complex acoustic behavior of periodic media in the ultrasonic regime.

Tension and Compression Properties of 3D-Printed Composites: Print Orientation and Strain Rate Effects

This study examines the impact of three factors on the tensile and compressive behaviour of 3D-printed parts: (1) the addition of short carbon fibres to the nylon filament used for 3D printing, (2) the infill pattern, and (3) the speed at which the materials are strained during testing. The results show that adding carbon fibres to the nylon filament reduces variability between tests and emphasises the effect of print orientation. When the infill pattern is aligned with the direction of loading, the tensile strength of all samples increases, with the largest increase of 100% observed in the carbon fibre-reinforced samples, compared to a 37% increase in the strength of nylon samples. The carbon fibre-reinforced samples are also highly dependent on strain rate, with a 60% increase in tensile strength observed at a faster testing speed of 300 mm/min (9 min−1) compared to 5 mm/min (15 min−1). Nylon samples show a decrease of approximately 10% in tensile strength at the same increased speed. The compressive strength of the composite samples increases by up to 130% when the print path is parallel to the loading direction. Increases of up to 50% are observed in the compressive modulus of the composite samples at a test speed of 255 mm/min (9 min−1) compared to 1.3 mm/min (0.05 min−1). Similar trends are not seen in pure nylon samples. This study is the first to report on the variation of Poisson’s ratio of short carbon fibre-reinforced 3D-printed parts. The results show increases of up to 34% and 76% in the tensile and compressive Poisson’s ratios, respectively, when printing parameters are altered. The findings from this research will contribute to the design and numerical modelling of 3D-printed composites.

A novel hybrid design and modelling of a customised graded Ti-6Al-4V porous hip implant to reduce stress-shielding: An experimental and numerical analysis

Stress shielding secondary to bone resorption is one of the main causes of aseptic loosening, which limits the lifespan of hip prostheses and exacerbates revision surgery rates. In order to minimise post-hip replacement stress variations, this investigation proposes a low-stiffness, porous Ti6Al4V hip prosthesis, developed through selective laser melting (SLM). The stress shielding effect and potential bone resorption properties of the porous hip implant were investigated through both in vitro quasi-physiological experimental assays, together with finite element analysis. A solid hip implant was incorporated in this investigation for contrast, as a control group. The stiffness and fatigue properties of both the solid and the porous hip implants were measured through compression tests. The safety factor of the porous hip stem under both static and dynamic loading patterns was obtained through simulation. The porous hip implant was inserted into Sawbone/PMMA cement and was loaded to 2,300 N (compression). The proposed porous hip implant demonstrated a more natural stress distribution, with reduced stress shielding (by 70%) and loss in bone mass (by 60%), when compared to a fully solid hip implant. Solid and porous hip stems had a stiffness of 2.76 kN/mm and 2.15 kN/mm respectively. Considering all daily activities, the porous hip stem had a factor of safety greater than 2. At the 2,300 N load, maximum von Mises stresses on the hip stem were observed as 112 MPa on the medial neck and 290 MPa on the distal restriction point, whereby such values remained below the endurance limit of 3D printed Ti6Al4V (375 MPa). Overall, through the strut thickness optimisation process for a Ti6Al4V porous hip stem, stress shielding and bone resorption can be reduced, therefore proposing a potential replacement for the generic solid implant.