Experimental and numerical investigation of 3D-Printed bone plates under four-point bending load utilizing machine...

Area of Science:

• Biomaterials Engineering
• Additive Manufacturing
• Orthopedic Implant Design

Background:

• Fused Deposition Modeling (FDM) offers potential for custom orthopedic implants.
• Processing parameters, especially layer thickness, critically affect FDM implant properties.
• Polylactic Acid (PLA) is a suitable material for biodegradable bone implants.

Purpose of the Study:

• To investigate the impact of layer thickness on the flexural properties of FDM-produced PLA bone plates.
• To develop and validate a finite element model for predicting the mechanical behavior of these implants.
• To determine the optimal layer thickness for enhanced implant performance.

Main Methods:

• Experimental testing of PLA bone plates fabricated with varying layer thicknesses using FDM.
• Development of a 3D finite element (FE) model incorporating the Gurson-Tvergaard (GT) porous plasticity model.
• Calibration of FE model parameters using tensile tests and machine learning algorithms.

Main Results:

• Flexural strength was inversely proportional to layer thickness, attributed to void variations.
• The FE model accurately predicted flexural behavior, with a maximum load error of 6.13%.
• An optimal layer thickness of 0.1 mm was identified for superior flexural strength and stiffness.

Conclusions:

• Layer thickness is a critical parameter influencing the mechanical integrity of FDM-printed PLA bone plates.
• The validated FE model provides a reliable tool for predicting implant performance.
• A layer thickness of 0.1 mm is recommended for manufacturing FDM-printed PLA bone implants with optimal mechanical properties.