We present a new approach to designing three-dimensional, physically realizable porous femoral implants with spatially varying microstructures and effective material properties. We optimize over a simplified design domain to reduce shear stress at the bone-prosthetic interface with a constraint on the bone resorption measured using strain energy. This combination of objective and constraint aims to reduce implant failure and allows a detailed study of the implant designs obtained with a range of microstructure sets and parameters. The microstructure sets are either specified directly or constructed using shape interpolation between a finite number of microstructures optimized for multifunctional characteristics. We demonstrate that designs using varying microstructures outperform designs with a homogeneous microstructure for this femoral implant problem. Further, the choice of microstructure set has an impact on the objective values achieved and on the optimized implant designs. A proof-of-concept metal prototype fabricated via selective laser melting (SLM) demonstrates the manufacturability of designs obtained with our approach.
Physically Realizable Three-Dimensional Bone Prosthesis Design With Interpolated Microstructures
Manuscript received June 13, 2016; final manuscript received November 29, 2016; published online January 24, 2017. Assoc. Editor: Kristen Billiar.
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Cramer, A. D., Challis, V. J., and Roberts, A. P. (January 24, 2017). "Physically Realizable Three-Dimensional Bone Prosthesis Design With Interpolated Microstructures." ASME. J Biomech Eng. March 2017; 139(3): 031013. doi: https://doi.org/10.1115/1.4035481
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