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research-article

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
a.cramer@uq.edu.au

Vivien J. Challis

School of Mathematics and Physics The University of Queensland
vchallis@maths.uq.edu.au

Anthony P. Roberts

School of Mathematics and Physics The University of Queensland
apr@maths.uq.edu.au

1Corresponding author.

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

Abstract

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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