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Three-dimensional-printed femoral diaphysis for biomechanical testing-Optimization and validation
Robert C Weinschenk1,2, Blaine M Oldham1, Kishore M Nagaraja3
1Department of Orthopaedic Surgery, The University of Texas Southwestern Medical Center, Dallas, Texas, USA.
Summary
3D-printed polylactic acid femurs offer an accessible and reproducible method for biomechanical studies. Optimized printing parameters successfully replicated the flexural properties of human femurs.
Area of Science:
- Biomedical Engineering
- Materials Science
- Orthopedic Biomechanics
Background:
- Developing cost-effective and reproducible models for biomechanical studies is crucial for orthopedic research.
- Human femoral diaphyses are complex structures requiring accurate mechanical emulation for effective study.
- Three-dimensional (3D) printing offers potential for creating customized biomechanical models.
Purpose of the Study:
- To design and fabricate inexpensive, accessible, and reproducible 3D-printed polylactic acid (PLA) models of human femoral diaphyses.
- To characterize the flexural biomechanical response of these 3D-printed models.
- To establish a design space for 3D-printed femurs that emulates the mechanical behavior of normal human femurs.
Main Methods:
- Polylactic acid (PLA) models of normal human femoral diaphyses were created using 3D printing technology.
- Models were subjected to three-point bending tests to evaluate their mechanical response.
- The influence of printing parameters (orientation, infill density, wall layers, resolution) on mechanical behavior was investigated.
Main Results:
- 3D-printed PLA femurs with 5% infill, 2-4 wall layers, and 200 µm resolution achieved a flexural strength of 184.8 ± 8.18 MPa.
- Models with 20% infill and six wall layers exhibited a flexural modulus of 18.54 ± 0.543 GPa.
- These results closely emulate established biomechanical data for normal human femurs.
Conclusions:
- Optimized 3D printing parameters can yield PLA models that accurately replicate the flexural biomechanics of human femoral diaphyses.
- These 3D-printed models represent a cost-effective and accessible resource for biomechanical research and surgical training.
- Further research including proximal and distal femur modeling and comprehensive testing could expand the utility of these models.
