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

Cervical spondylosis and spinal injuries are increasing public health concerns, often associated with prolonged 'text neck' posture, sedentary lifestyles, and trauma. Artificial cervical disc replacement (ACDR) offers a treatment option. However, current prostheses are limited by narrow eligibility criteria, risks of ectopic ossification that may result in spinal fusion, and potential issues with subsidence or displacement. This study presents a novel, porous-structured prosthesis designed for implantation after bone resection, expanding ACDR applicability by enabling complete lesion removal. Developed through finite element analysis and fabricated via laser powder bed fusion using Ti-6Al-4V extra low interstitial alloy, the prosthesis is optimized for both biomechanical and biological compatibility. Tests indicate that the porous structure supports bone ingrowth, with mechanical properties closely matching those of human bone, effectively mitigating stress shielding. The gradient mechanical properties enhance integration with autologous bone, reducing postoperative complications. This work establishes a foundation for using porous bionic implants in cervical spine therapy, with broader implications for orthopedic and biomedical applications requiring high biomechanical compatibility.