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Kang 2012
Kang 2012
Journal of Biomechanics
journal homepage: www.elsevier.com/locate/jbiomech
www.JBiomech.com
a r t i c l e i n f o abstract
Article history: The future development of bio-integrated devices will improve the functionality of robotic prosthetic
Accepted 9 June 2012 limbs. A critical step in the advancement of bio-integrated prostheses will be establishing long-term,
secure fixation to the remnant bone. To overcome limitations associated with contemporary bone-
Keywords: anchored prosthetic limbs, we established a paradigm for developing and fabricating novel orthopedic
Orthopedic implant design implants undergoing specified loading. A topology optimization scheme was utilized to generate
Topology optimization optimal implant macrostructures that minimize deformations near the bone-implant interface.
Solid freeform fabrication Variations in implant characteristics and interfacial connectivity were investigated to examine how
Microstructure these variables influence the layout of the optimized implant. For enhanced tissue integration, the
optimally designed macroscopic geometry of a titanium (Ti)-alloy implant was further modified by
introducing optimized microstructures. The complex geometries of selected implants were successfully
fabricated using selective laser sintering (SLS) technology. Fabrication accuracy was assessed by
comparing volumes and cross-sectional areas of fabricated implants to CAD data. The error of fabricated
volume to CAD design volume was less than 8% and differences in cross sectional areas between SEM
images of fabricated implants and corresponding cross sections from CAD design were on average less
than 9%. We have demonstrated that this computational design method, combined with solid freeform
fabrication techniques, provides a versatile way to develop novel orthopedic implants.
& 2012 Published by Elsevier Ltd.
Fig. 3. The topology optimization distributed more material in high stress regions
such that the stiffness of the system was maximized for a given material volume
fraction. In this example, the entire interfacial zone was assumed to be
trabecular bone.
interest (ROI) that matched the cylindrical design domain of the optimization
scheme (6.4 mm diameter by 6.4 mm height). Implant material was thresholded
to calculate the volume fraction of the ROI. For the second method of assessing
manufacturing accuracy, cross-sections from porous optimized implants were
imaged with a backscatter scanning electron microscope (SEM). To do this, two Fig. 4. Implant material, design domain size and interfacial connectivity were
implants were embedded in methylmethacrylate and cut with a diamond saw varied to explore the effects of these variables upon the topology optimization
(IsoMet Low Speed Saw, Buehler LTD, Lake Bluff, IL) generating roughly 1000 mm results. Each row of implants represents a different design domain size (67%, 42%
thick sections; one implant was sectioned orthogonal to the long axis (transverse or 25% of the overall radial dimension). (A) and (D) are with fibrous tissue along
sections) and the other parallel (longitudinal sections). Sections were wet polished the entire interface, (B) and (E) are with fibrous tissue interface along the implant
to a final thickness of 800–900 mm, carbon-coated and imaged at 10 magnifica- sides and a bony interface along the base, and (C) and (F) are with bony tissue
tion with an Amray SEM (model 1810, KLA-Tencor Corp., Milpitas, CA). Using along the entire interface.
Matlab (v 7.11, The MathWorks Inc., Natick, MA), digital SEM cross-sections were
then quantitatively compared to matched CAD cross-sections by overlaying
images at a pixel size of 18 mm. Each implant pixel was then categorized as
overlap (both SEM and CAD), SEM only or CAD only. For each cross-section, two introducing a fibrous tissue zone around the design domain, the
error percentages were calculated: (1) excess material was indicated by the pixel hollowed space filled with more implant material to increase the
number of SEM only and (2) deficient material by the pixel number of CAD only. overall stiffness of the bone-implant system. Varying implant
Both error percentages were normalized by the number of overall CAD pixels material only affected the topology when there was direct bone
within the cross-section.
apposition along the entire interface (i.e. both sides and bottom).
Specifically, the titanium implant had a large hollow base without
any implant material, while the porous tantalum implant had a
3. Results central column within this hollow region that connected the
implant and bone along the base of the design domain. Variations
To minimize total deformation under uni-axial loading, the in the size of the design domain had limited effects on topology.
optimization algorithm assigned higher density values to angled For fabrication, a candidate design was chosen that repre-
elements that generally formed a bell-shaped topology (Fig. 3). sented a titanium implant with a large design domain and
These higher density regions corresponded to finite elements trabecular bone interface (no fibrous tissue). As an additional
under high von Mises stresses. The stress distribution revealed design step, this solid macrostructure was transformed into a
that load could be transmitted to the bone along the side and hierarchical scaffold by mapping microstructure sub-units to the
bottom of the design domain. design domain’s density distribution (Fig. 5). This added process
Applying the FE topology optimization to the permutations of created a porous implant structure designed to facilitate bone
implant characteristics and interface connectivity resulted in the infiltration and improve implant fixation. The solid, macrostruc-
development of 18 macrostructural implant designs (Fig. 4). In ture and porous scaffold designs were then converted to CAD
general, many of the model permutations resulted in subtle format for fabrication (Fig. 6).
changes to the implant’s topology. The most substantial effect Both optimized implant designs were successfully fabricated
on design topology was associated with a fibrous or bone tissue using SLS technology (Fig. 7). In general, the topology of the
interface. Without a fibrous tissue zone (i.e. direct bone integra- fabricated implants matched the CAD data; however, some of the
tion), the topology optimization tended to develop a bell-shaped smaller pores associated with the porous design were filled with
implant design with a hollow region near the base. Upon excess Ti-alloy. Volume fractions of the manufactured implants,
2244 H. Kang et al. / Journal of Biomechanics 45 (2012) 2241–2247
4. Discussion
Fig. 7. Scanning electron microscopy (SEM) images show implants fabricated with selective laser sintered (SLS) technology.
Fig. 8. For assessing fabrication accuracy, implant cross-sections were imaged with SEM and then overlayed with CAD cross-sections.
2246 H. Kang et al. / Journal of Biomechanics 45 (2012) 2241–2247
Table 2
Comparison of implant cross-sections (Fabricated versus CAD).
Section Average
% Excess Material (SEM only) 11.7 7.0 8.8 11.4 5.3 8.7 9.5 8.9
% Deficient Material (CAD only) 4.5 6.2 4.8 2.6 12.6 10.7 6.6 6.9
During the optimization process, implant material was removed in afterwards by using additional design and analysis tools. There
low von Mises stress regions and assumed to be replaced with void. are also limitations associated with the SLS technology we used to
This would be equivalent to the initial post-operative period where fabricate two optimized implant designs. In general, the small
bone ingrowth would have not yet occurred. Alternatively, one pores of the hierarchical scaffold were smaller than designed due
could modify the material interpolation such that lower modulus to excess implant material. These pores were designed to be
(trabecular bone) and higher modulus (implant metal) materials are 350 mm, which is near the fabrication resolution of contemporary
incorporated into the design domain. This would assume full integra- SLS systems. Additionally, material properties of the implant will
tion of the host bone to the implant surface. However, since the be dependent upon SLS fabrication parameters (e.g. powder size
modulus of bone is less than that of the implant materials, the effect and laser temperature). Post-processing, like annealing, can be
of introducing low stiffness material into the design domain may not used to alter material properties, such as toughness and fatigue
significantly impact the optimization results. life (Hollander et al., 2006).
There are several limitations associated with the implant
design scheme, topology optimization and SLS fabrication tech-
nology. Our FE model was a generic representation of a small 5. Conclusions
bone-implant system exposed to simplified boundary conditions.
Only uni-axial loads were applied to the implant for this initial We successfully demonstrated the development of implant
iteration of our model. While this is not a complex loading designs for favorable bone fixation using topology optimization.
condition, our goal at this stage was to establish a design This approach allows for designing novel orthopedic implants for
paradigm for generating and evaluating novel implant structures; specific loading environments that have intricate porous archi-
we did not seek to create an implant for clinical use. Focusing on tectures for tissue integration. Candidate implants were then
uni-axial loads also enabled us to evaluate our fabricated successfully fabricated using SLS technology with medical-grade
implants in a companion experiment that incorporated in vivo Ti-alloy. The fabricated implants closely matched CAD data,
application of cyclic, tension-compression loads (Long et al., generally within 7 10%. The next step will be testing our implants
under review). Another limitation of our FE model was using in an in vivo environment to identify key aspects of the designs
the 451 wedge to represent the entire 3D structure. This was done that promote osseointegration.
to improve the computational efficiency of the optimization
algorithm; however, the wedge mesh (and the associated bound- Conflicts of interest
ary conditions) created stress artifacts near the edges. In some
cases, these artifacts affected the topology of the optimized The authors have no conflicts of interest to disclose.
implant. For example, the small radial projections near the top
of the solid design fabricated from Ti-alloy are artifacts
(Figs. 6 and 7). In all cases, however, these artifacts were small Acknowledgments
relative to the global optimized structure. While there were
minor issues with our design scheme, it is important to note that This work was supported by a Multi-disciplinary University
the FE model could be modified and refined to develop other Research Initiative (MURI) from the Army Research Office (Pro-
implant structures, in which case the framework of our design posal 50376-LS-MUR, Grant W911NF-06-0218) as well as the
paradigm is still applicable. Regarding limitations of topology National Institutes of Health (Grants 5T90-DK070071, 5RO1-
optimization methods, future iterations of our optimization AR051504 and 1R01AR053379).
scheme could benefit from next generation software that would
permit modeling of more complex physical phenomena. For References
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