Physically Realisable 3D Bone Prosthesis Design with Interpolated Microstructures

[+] Author and Article Information
Andrew D. Cramer

School of Mathematics and Physics The University of Queensland

Vivien J. Challis

School of Mathematics and Physics The University of Queensland

Anthony P. Roberts

School of Mathematics and Physics The University of Queensland

1Corresponding author.

ASME doi:10.1115/1.4035481 History: Received June 13, 2016; Revised November 29, 2016


We present a new approach to designing three-dimensional, physically realisable porous femoral implants with spatially varying microstructures and effective material properties. We optimise 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 optimised 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 optimised implant designs. A proof-of-concept metal prototype fabricated via selective laser melting demonstrates the manufacturability of designs obtained with our approach.

Copyright (c) 2016 by ASME
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