Design and manufacturing of a bionic cervical interarticular prosthesis based on L-PBF

Area of Science:

• Biomedical Engineering
• Orthopedic Surgery
• Materials Science

Background:

• Cervical spondylosis and spinal injuries are rising public health issues linked to modern lifestyles and trauma.
• Current artificial cervical disc replacement (ACDR) methods have limitations including strict eligibility, ectopic ossification, and implant instability.
• There is a need for improved ACDR prostheses that are more versatile and offer better integration with the patient's anatomy.

Purpose of the Study:

• To introduce a novel porous-structured prosthesis for artificial cervical disc replacement (ACDR).
• To expand ACDR applicability by enabling complete lesion removal and accommodating a wider range of patients.
• To optimize the prosthesis for biomechanical and biological compatibility, enhancing integration and reducing complications.

Main Methods:

• Finite element analysis was employed to design and optimize the prosthesis.
• The prosthesis was fabricated using laser powder bed fusion with Ti-6Al-4V extra low interstitial alloy.
• Mechanical and biological compatibility tests were conducted to evaluate performance.

Main Results:

• The porous structure demonstrated potential for bone ingrowth, promoting biological integration.
• The prosthesis exhibited mechanical properties closely matching human bone, effectively mitigating stress shielding.
• Gradient mechanical properties facilitated enhanced integration with autologous bone, suggesting reduced postoperative complications.

Conclusions:

• The developed porous bionic implant represents a significant advancement in cervical spine therapy.
• This novel prosthesis broadens the scope of ACDR, offering a viable option for patients previously ineligible.
• The findings lay the groundwork for future applications of porous bionic implants in orthopedic and biomedical fields requiring high biomechanical compatibility.