Finite element modelling and characterization of 3D cellular microstructures for the design of a cementless biomimetic porous hip stem

Abstract

Titanium porous cellular microstructures are commonly used in bone mimetic implants. The orientations of the internal strut architectures of these microstructures affect the mechanical performance under various loads; however, poor architectural designs may result in their failure. Three-dimensional (3D) finite element models of cubic, diamond, and body-centered cubic (BCC) geometries were constructed with 1–4 numbers of unit cells and 4–10-mm unit cell size. Mechanical testing of the finite models of the cubic, diamond, and BCC structures with porosities of 20–90% was performed under compression, bending, and torsional loads. The BCC structure showed moderate and relatively isotropic mechanical properties compared with those of the diamond and cubic structures. A design space for a BCC porous structure with a porosity of 40–65% was estimated to model a complete porous stem to mimic the bone properties. Furthermore, the stems with the determined porous mechanical properties of the BCC microstructures with 20–90% porosities were tested under physiological loading conditions. It was found that a porosity of 47.3% of the BCC structure exhibits the closest stiffness (469N/mm) to an intact bone (422N/mm). This was predicted by our suggested design space of the porosity.