Shaping scaffold structures in rapid manufacturing implants: A modeling approach toward mechano-biologically optimized configurations for large bone defect

Large segmental bone defects remain a clinical challenge. Titanium lattice-structured implants in combination with laser sintering technology promises to be an alternative to bone grafting in the treatment of critical sized bone defects. Laser sintering allows the rapid manufacturing of patient specific 3D-structured scaffolds with highly interconnected macroporous networks and tunable mechanical properties. Unknown remains to what degree the mechanical properties of these implants could be tuned, without leading to mechanical failure but still providing adequate mechanical stimuli for tissue ingrowth. The aim of this study was to evaluate various implant designs for their mechanical potential towards (a) optimized safety against stress failure and (b) optimal intrastructural straining for bone ingrowth. Finite element analyses of several lattice-structured configurations were performed. Results illustrated a strong influence of the configuration on the load carrying capacity of the constructs. The likelihood of mechanical failure was predicted to be highly dependent on structure configuration with little influence of implant porosity. Increasing porosity did not result in an increase in the implant intrastructural straining in all configurations; however, the lattice configuration was the determinant factor for implant load transfer capacity. This study provides a framework for the design of effective implants with open pore structures to ensure mechanical stability as well as promote mechanical stimulation and encourage in vivo osseointegration. (C) 2012 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 2012.