Optimizing Orthopaedic Bone Plates for Directed Energy Deposition with Generative Design and Topological Optimization Approaches

Abstract

Directed Energy Deposition (DED), a metal additive manufacturing technique, shows promise for future orthopaedic applications, especially in bone plate manufacturing. The need for patient-specific solutions in orthopaedics is growing, driven by the limitations of traditional bone plates made from stainless steel or titanium alloys and the rising incidence of complex fractures. This paper explores the design of orthopaedic bone plates using Generative Design (GD) and Topological Optimization (TO), aimed at eventual production through DED. By focusing on design, the research addresses challenges like stress shielding, caused by the modulus disparity between conventional plate materials and natural bone. Significant findings include mass reductions of 43.7% and 44.2% for GD designs GD1 and GD2, respectively, and a 36% reduction for the TO design TO1, enhancing biomechanical performance with improved strain values. The findings demonstrate GD’s effectiveness in generating anatomically congruent implants, showcasing advancements in personalized care and fracture treatment. The integration of GD and DED within the Design for Additive Manufacturing (DfAM) framework offers a promising pathway for future research focused on refining patient-specific designs and manufacturing processes, aligning with the evolving needs of orthopaedic treatments.