Design of functionally graded porous lattice structure tibial implant for TAR

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Use of porous lattice structures and functionally graded (FG) implants in orthopaedic applications has emerged as a promising solution to reduce stress shielding. However, there is a notable research gap in examining the effects of post-operative scenarios within the lattice pores and different porosity distribution laws in functionally graded porous lattice structure (FGPLS) implants on the biomechanical performance of tibial implant for total ankle replacement (TAR). The objective of the study is to investigates the effects of both post-operative tissues and various porosity distribution laws on the biomechanical performance of tibial implant for TAR and proposes a new design strategy. CAD models for lattice structures at various porosities were developed to incorporate the effects of post-operative tissues such as fibrous tissue, cartilage, immature bone, and mature bone. The pore spaces of these lattice structures were assumed to be filled with the post-operative ingrowth tissues. The lattice structure and these tissues together form the Representative volume element (RVE), whose effective properties were calculated using Asymptotic homogenization (AH) technique. Equations linking mechanical properties and porosity were established and used to assign mechanical properties to macro-FE models of FGPLS tibial implants based on three different power laws i.e. n = 0.1,1 and 5. Macro-FE models for intact and implanted tibia bones were developed using homogeneous properties of cortical bone and heterogeneous cancellous bone properties. The proximal part of the tibia was fixed, and a compressive load was applied through the anterior nodes of the meniscal bearing to represent dorsiflexion loading during normal walking. The Finite Element Analysis (FEA) was utilized to investigate the biomechanical performance of these implanted models in terms of stress distribution in the tibia bone and implant-bone micromotion. A comparison was made between models with solid metallic implants and those with FGPLS implants. Additionally, models with varying post-operative tissues in the pore space were compared, as well as models with different porosity variation laws were also compared. Results demonstrated that models implanted with FGPLS implants having porosity variation based on power law n = 0.1 showed increased bone stress and micromotion compared to those with solid metallic implants. Specifically, in models with FGPLS implants with porosity variation based on a power law of n = 0.1, the bone area with stress ranging from 2–5 MPa increased significantly in the periprosthetic region compared to models with solid metallic implants. The bone stress value for the majority of the region above the medial and lateral peg increased from 1–2 MPa to 2–5 MPa. Although there was a slight increase in micromotion values, they remained below the acceptable threshold of 50 µm. Models with porosity variations based on power laws n = 1 and n = 5 exhibited similar bone stress and micromotion results as solid metallic implants. Additionally, no significant difference in bone stresses was observed for different stages of bone ingrowth at pore space. These findings indicate that both the porous structure and porosity distribution within the implant significantly influence the biomechanical performance of tibial implants for TAR. So, it can be concluded that FGPLS implants with power law n = 0.1 are effective in reducing stress shielding and supporting the long-term survival of TAR by increasing bone stress and reducing the chances of aseptic loosening due to implant induced adaptive bone remodelling.