Materials Today: Proceedings 50 (2022) 585–592

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Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

3D printing of lumbar spine cages manufactured through: Finite element

analysis and experimental validation
Rahul Wandra
School of Mechanical Engineering, Lovely Professional University, Punjab, India

a r t i c l e i n f o a b s t r a c t

Article history: Lower back pain is one of the most common problems amongst people in this fast-paced life, often caused
Received 25 December 2020 by degenerative disc diseases in the lumbar region of the spine. Many conventional techniques are com-
Received in revised form 9 January 2021 mercially available in order to manufacture spinal cages; however, three-dimensional (3D) printing pro-
Accepted 11 January 2021
vides the flexibility of creating patient-specific spinal cages depending on the patient’s condition. Indeed,
Available online 19 February 2021
solid cages provide the strength but lack in reducing stress-shielding; hence, creating a porous structure
inside the spinal cages can help in reducing the stress shielding effect. In the present work, two cages
Keywords:
(solid and Gyroid structure porous plif) have been made of titanium ELI grade by using direct metal laser
Titanium
Finite element analysis
sintering (DMLS) technique. Compression and fatigue test has been performed in the simulated environ-
Direct metal laser sintering ment with the help of finite element analysis (FEA) and, thereafter, compared with the physical results. It
3D printing has been found that Gyroid structured porous cage developed more concentration of the stress when
Lumbar spine cage compared to the solid cage; however, it efficiently reduced the stress shielding effect and will promote
the bone in-growth.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Con-
ference on Functional Material, Manufacturing and Performances.

1. Introduction such as high corrosion resistance, superior strength to weight ratio,

In today’s fast paced life, humans are involved in demanding
work routines which demand several hours of sittings and ulti-
mately are injuring their intervertebral disc, directly or indirectly
[1]. Considering older population, as per the United Nations Eco-
nomic and Social Commission for Asia and the Pacific (UNESCAP),
people aged above/about 65 years would be more severely affected
by the issues as it has been estimated that there would be an
increase of 20% patients by 2050 [2]. Therefore, owing to the boost
in the demand of surgical devices and implants, many researchers
already started working on developing better materials and
designs which can take care of the stress distributions within the
inter vertebral discs [3,4]. Indeed, numerous conventional tech-
niques can fix the lower portion of vertebrate and load sustainabil-
ity; however, the accuracy and services of such practices is usually
questionable [5,6].
The use of metal implants has seen a tremendous growth over
past decade. The importance of stainless steel, cobalt chrome,
and titanium has been researched for its feature provided by them
E-mail address: rahul.mechlpu@gmail.com
excellent biocompatibility, and low elastic modulus compared to
other metals, high durability, and their capability of osseointegra-
tion [7,8]. Despite having an edge among the various classes of bio-
materials, titanium (Ti) is often preferred as an implant material
owing to its various physio-mechanical, chemical, and bio-
compatibility [9–33]. However, the use of a solid Ti implant is
always unfavourable owing to its unmatched mechanical charac-
teristics in response of host bone and other tissues [34,35]. How-
ever, this issue could be easily tackled through reducing the
stress shielding effect by making the resulting implant as porous
structures [36]. There are numerous techniques to develop
porous-structure, but 3D printing is one of the best method [36–
50]. Porous Ti6-Al-4V alloy has been manufactured by electron
beam melting technique with an objective to contribute for recon-
struction of craniofacial defects [51]. Oh et al. sintered spherical
unalloyed Ti powders with and without applied pressure and
achieved a porosity range of 5–37% [52]. Thieme et al. produced
Ti-foams with a gradient in porosity by sintering a stack of three
powder layers with different particle sizes and silicon contents
[53]. Blinova et al. used two types of porous implants such as reg-
ular structures and irregular structure and performed in-vitro test-

https://doi.org/10.1016/j.matpr.2021.01.290
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Conference on Functional Material, Manufacturing and Performances.
R. Wandra Materials Today: Proceedings 50 (2022) 585–592

ing and observed better osseointegration in the implant with irreg-
ular structure [54].
There are various technologies (such as powder metallurgy,
temporary space holding, replication, chemical vapour deposition,
electric field assisted sintering, etc.), however, these technologies
cannot meet-up with the mass customization required in today’s
manufacturing era [55]. Moreover, digitization of these technolo-
gies is extremely difficult owing to which utilization of the
resources for manufacturing is sometimes unbearable when it
comes to job or batch productions. Three-dimensional printing
(3DP), usually referred to as next generation manufacturing,
enables the manufacturing to be completely automatic as the this
technology merely depends on human governing and generally
takes all the inputs through computer aided devices [56]. Specifi-
cally, in the area of biomedicine, this technology could be clubbed
with the computer tomography or magnetic resonance imaging
based scan data, thereby, making the manufacturing possible
through the digital networking [57,58]. Additionally, it is also pos-
sible to make necessary changes in the design of the printable
structures after their pre-analysis by using finite element analysis
(FEA) and other suitable simulation software packages.
In the present work, an effort has been made to perform the
comparative analysis of in-vivo loading between the two different
types of cages for L4-L5 lumbar spinal joint, such as solid and
Gyroid structure porous plif, through FEA as well as physical test-
ing performed on 3D printed samples after developing customized
fixtures. The results highlighted that Gyroid porous cage has high
stress values compared to solid cage, however, at the same time
the former helped in reducing the stress shielding effect and will
promote bone in-growth and faster inter-body fusion rate.
not high enough to melt the articles completely, but does cause
the particles to stick together into a semi solid structure. In the
next step, a high voltage laser beam is used to selectively hit areas
of the powder according to the pre designed computer-aided
design (CAD) model. The beam causes the particles of semisolid
layer to fuse together. Once the laser beam has finished melting
the 2D pattern of the layer the base plate is lowered and a rake
is used to apply a fresh layer of powder. At the end of the process,
the semi-solid structure of particles can be removed in a so-called
‘powder recycling system’ where compressed air is used to blast
the structure with metal particles of the same type as the build
powder. After the parts are printed, the parts with build plate were
heat treated up to 800 °C (VERSATREAT IMF – 144) in order to
eliminate the thermal stresses. Wire-cut electric discharge
machining has been used to separate the base place and the fabri-
cated cages. Finally, shot peening (SEC-1500 TWIN SPL) has been
used to improve the surface finish of the resulting cages (refer
Fig. 2 for the micrograph of the finally resulted 3D printed cage).

2. Materials and method

In the present work, highly pure spherical Ti-6Al-4V (Grade 23)

ELI has been used for developing test specimens. Fig. 1 shows the
scanning electron micrographic (SEM) and energy dispersion spec-
troscopy (EDS) plots of the raw Ti-6Al-4V. The designed cage will
be manufactured using Direct Metal Laser sintering (DMLS: EOS
M290 Metal Printer) based 3D printing technology. In 3D printing,
the fabrication of a 3D object takes place inside the build chamber
of the 3D printer and starts with a solid metal base plate on which
a thin layer (typically < 100 mm) of metal powder is applied. The Fig. 2. SEM of finally produced 3D printed cage.
layer is then heated by a laser beam to a temperature which is

(a) (b)
Fig. 1. SEM (a) and EDS (b) plots for raw Ti-6Al-4V alloy.

586
R. Wandra
(a)
(c)
Fig. 3. FEA fatigue test results for solid cage; damage (a), long-life (b), SMAX (c), and FOS (d).
The FEA analysis of the designed lumbar cages has been done in
the following steps: Designing: The designing of cage was done in
modelling software SOLIDWORKS. In this, the cage size accounted
is 8  10  22 mm. Here, the amount of porous structure that
needed to be created was extrude-cut from the solid cage. Surface
meshing: The designed cage was exported in .STL format to 3Matic
medical software where its surface meshing was done so that the
triangles formed on the cage surface give precise result during
analysis. The nodes selected for loading conditions during analysis
were from surface mesh. Creation of porous structure: The surface
meshed cage was then exported to SimpleWare Scanip software to
create porous structure from internal structure wizard where the
design of porous structure was decided as Gyroid. Assembly of cage
with fixture/ bone: The solid cage and porous cage were then
assembled in 3-matic medical with their fixtures and L4-L5 verte-
brate. After this, a non-manifold assembly was created and its vol-
ume meshing is done. The non-manifold assembly was then split
into parts based upon their volume sets and the parts are exported
to ABAQUS for FEA analysis. FEA of solid and porous cage: FEA in
cage helped to predict the manner in which the surrounding verte-
brate was impacted by stresses transfer. Transfer of load from cage
to its vertebrate was based on type of loading, the cage-vertebrate
interface, the size of cage, shape and characteristics of the cage sur-
face and the quality of the surrounding vertebrate. FEA allowed
researchers to predict stress distribution in contact area of implant
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Materials Today: Proceedings 50 (2022) 585–592
(b)
(d)
with surrounding bones. The imported .INP file of the assembly
was then given the material properties of bone, titanium for cage.
After that, the type of analysis was selected which in this case is
dynamic implicit. Further, the number of iterations was given fol-
lowed by giving interaction property between the parts. The inter-
action between cage and vertebrate was tie contact.
The long-term stability and mechanical properties of solid and
porous implants was examined under static condition. The samples
of solid and porous cage were examined in compression test under
universal testing machine using 10,000 N load cell, according to
the ASTM-F1717, the loading condition is maximum given to
500 N hence stress, strain at 500 N was taken in consideration
and was compared to FEA analysis done at 500 N.
3. Results and discussion
The Fig. 3 shows the fatigue test defines four aspects of the solid
cage. This test was carried out on 3000 N. From the Fig. 3 (a), it can
be seen that the highest damage is 105, as indicated by red colour.
From the log, refer Fig. 3 (b), life of solid cage has been determined
as 109 cycles. This means that at every 109 cycles the node will
completes its one life on a given load. The blue portion shows that
it will be the first of the parts to break from there. The SMAX in the
Fig. 3 (c) showed that the highest stress obtained during fatigue
R. Wandra
Fig. 4. FEA fatigue test results for Gyroid cage (solid-porous: left and pure porous: right); damage (a), long-life (b), and SMAX (c).
analysis is 80,330 MPa, in direction opposite the load applied.
Whereas, the lowest stress acting on the cage is
7.618  105 MPa, acting towards the load applied. However, in
case of porous cage, as per Fig. 4, the early damage will be caused
at 105 cycles on node 84,374 of element PT_POROUS_1.1. The log-
life repeats, such as node 105,425 of element PT_POROUS_1.1266,
has lost its life at 109 cycles, being the longest in the Gyroid cage.
The maximum stress, SMAX, caused on node 4978 of element
PT_SOLIDNEER1_1.6084 was 1.256  106 MPa at 3000 N. To relate
SMAX and log-life repeats, it can be seen that the element with
highest SMAX has lowest log-life repeats.
In the compression test of solid cage, the load on the upper fix-
ture was given as 500 N. The maximum stress obtained was about
218.2 MPa on node 2634 of the solid cage as shown in Fig. 5(a). The
maximum displacement on the cage was 0.0034 mm on node
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Materials Today: Proceedings 50 (2022) 585–592
(a)
(b)
(c)
PT_SOLID_1.2600, refer Fig. 5(b). The stress obtained was much
safe as the maximum stress limit for titanium spinal cage is
950 MPa. The Fig. 5(c) shows logarithmic strain. Noticeably, the
strain is less than 1%, equal to engineering strain, thus, the loga-
rithmic strain in this case is 0.000757. However, in case of Gyroid
cage (refer Fig. 6), the maximum stress acting on the solid-porous
cage is 628.8 MPa and the stress distributed from solid frame to
porous structure is 105.7 MPa. This means that approximately
16% of stress was distributed from solid frame to porous structure.
It can also be seen that maximum displacement on solid-porous
cage is 0.022 mm and on porous structure is 0.0211 mm; hence,
this can be seen that the displacement occurs on same element.
The solid cage was tested on 10KN load cell Universal Testing
Machine and the conditions to stop the test were either on the
breakage of solid cage or up to 10KN load. It has been found from
R. Wandra
(a)
(c)
Fig. 5. FEA compression test results of solid cage; (a) stress, (b) displacement, and (c) logarithmic strain.
the test that the stress corresponds to 500 N in the solid cage was
248 MPa, however, the respective strain 0.556. However, in case of
Gyroid structured porous cage, it has been found that the stress
corresponds to 500 N of load was 704.9 MPa, whereas, the respec-
tive strain was 2.131. The stress and the strain in the later case
were quite higher than the former. On differentiating the results
of solid and Gyroid structured cage, refer Table 1, it can be seen
that both type of cages are safe when it comes to load bearing abil-
ity of the structures.
4. Conclusions
On the basis of observations made in the present work, follow-
ing conclusions could be drawn:
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Materials Today: Proceedings 50 (2022) 585–592
(b)
 FEA analysis of solid cage at 500 N resulted in stress value of
218.2 MPa, whereas, the mechanical compression test of the
solid cage caused stress of 248.5 MPa. Therefore, the predicted
and actual performance of the designed solid cage is approxi-
mately similar.
 Similarly, FEA analysis of Gyroid cage at 500 N resulted
in stress value of 628.8 MPa, whereas, the mechanical
compression test showed a nearby observation of
704.9 MPa.
 Fatigue test showed that porous Gyroid cage had less log-life
repeats than solid. However, the porous structure will help bone
in-growth. Further, the fatigue damage was caused at 3000 N
cyclic loading. Indeed, the stress shielding effect of solid cage
was greater than Gyroid cage.
R. Wandra Materials Today: Proceedings 50 (2022) 585–592

(a)

(b)

(c)
Fig. 6. FEA compression test results for Gyroid cage (solid-porous: left and pure porous: right); stress (a), displacement (b), and logarithmic strain (c).

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R. Wandra Materials Today: Proceedings 50 (2022) 585–592

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