Generation of Customized Bone Implants from CT Scans Using FEA and AM.

Area of Science:

• Biomedical Engineering
• Materials Science
• Orthopedic Surgery

Background:

• Additive manufacturing (AM) enables personalized medical devices, offering advantages over traditional methods for complex geometries.
• Fused filament fabrication (FFF) is a key AM technology for producing intricate designs.

Purpose of the Study:

• To develop a methodology for replacing a pathological talus bone with a custom-made implant using AM.
• To evaluate the feasibility and material suitability for 3D-printed talus bone reconstruction.

Main Methods:

• Generating a parametric solid model of the talus from patient CT scans of the healthy contralateral bone.
• Utilizing finite element analysis (FEA) for material selection and structural simulation.
• Producing the personalized talus implant using FFF technology.

Main Results:

• High geometric accuracy was achieved in the 3D-printed models.
• Computational time was significantly reduced compared to conventional approaches.
• Polyetheretherketone (PEEK) was identified as the most suitable material for talus bone replacement.
• Successful printing of multiple talus bone specimens was demonstrated.

Conclusions:

• The developed AM methodology provides a viable approach for creating patient-specific talus bone implants.
• FFF technology combined with FEA enables efficient and accurate production of customized orthopedic devices.
• PEEK shows promise as an effective biomaterial for talus reconstruction.