Exploring the optimal mechanical properties of triply periodic minimal surface structures for biomedical applications: A Numerical analysis

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Currently, cutting-edge Additive Manufacturing techniques, such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM), offer manufacturers a valuable avenue, especially in biomedical devices. These techniques produce intricate porous structures that draw inspiration from nature, boast biocompatibility, and effectively counter the adverse issues tied to solid implants, including stress shielding, cortical hypertrophy, and micromotions. Within the domain of such porous structures, Triply Periodic Minimal Surface (TPMS) configurations, specifically the Gyroid, Diamond, and Primitive designs, exhibit exceptional performance due to their bioinspired forms and remarkable mechanical and fatigue properties, outshining other porous counterparts. Consequently, they emerge as strong contenders for biomedical implants. However, assessing the mechanical properties and manufacturability of TPMS structures within the appropriate ranges of pore size, unit cell size, and porosity tailored for biomedical applications remains paramount. This study aims to scrutinize the mechanical behavior of Gyroid, Diamond, and Primitive structures in solid and sheet network iterations within the morphological parameter ranges suitable for tasks like cell seeding, vascularization, and osseointegration. A comparison with the mechanical characteristics of host bones is also undertaken. The methodology revolves around Finite Element Method (FEM) analysis. The six structures are originally modeled with unit cell sizes of 1, 1.5, 2, and 2.5 mm, and porosity levels ranging from 50% to 85%. Subsequently, mechanical properties, such as elasticity modulus and yield strength, are quantified through numerical analysis. The results underscore that implementing TPMS designs enables unit cell sizes between 1 and 2.5 mm, facilitating pore sizes within the suitable range of approximately 300–1500 μm for biomedical implants. Elasticity modulus spans from 1.5 to 33.8 GPa, while yield strength ranges around 20–304.5 MPa across the 50%–85% porosity spectrum. Generally, altering the unit cell size exhibits minimal impact on mechanical properties within the range above; however, it's noteworthy that smaller porosities correspond to heightened defects in additively manufactured structures. Thus, for an acceptable pore size range of 500–1000 μm and a minimum wall thickness of 150 μm, a prudent choice would involve adopting a 2.5 mm unit cell size.