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Potential Applications of Additive Manufacturing in Intervertebral Disc Replacement Using Gyroid Structures with

Leandro Hippel1,2, Jan Mussler1,2, Dirk Velten2

  • 1G.E.R.N. Center for Tissue Replacement, Regeneration & Neogenesis, Department of Orthopedics and Trauma Surgery, Medical Center-Albert-Ludwigs-University of Freiburg, Faculty of Medicine, Albert-Ludwigs-University of Freiburg, Hugstetter Straße 55, 79106 Freiburg, Germany.

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|February 27, 2026
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Summary
This summary is machine-generated.

Researchers explored thermoplastic polyurethane (TPU) filaments for 3D-printed intervertebral disc replacements. Four TPU materials met mechanical compression requirements, indicating suitability for artificial disc applications.

Keywords:
3D-printingadditive manufacturingfused deposition modeling FDMgyroidintervertebral discmechanical properties

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Area of Science:

  • Biomaterials Engineering
  • Orthopedic Biomechanics
  • Additive Manufacturing

Background:

  • Intervertebral disc degeneration is a common condition linked to disc herniation.
  • Degeneration results from annulus fibrosus failure, impacting shock absorption.
  • This study investigates thermoplastic polyurethane (TPU) filaments for 3D-printed disc replacements.

Purpose of the Study:

  • To evaluate additional thermoplastic polyurethane (TPU) filaments for additively manufactured intervertebral disc replacements.
  • To assess the mechanical properties of 3D-printed discs under compression and tension.

Main Methods:

  • Disc-shaped specimens (Ø50 × 10 mm) were fabricated using fused deposition modeling (FDM) with gyroid infill structures.
  • Four TPU filaments were tested across 36 parameter combinations.
  • Tensile and uniaxial compression tests were performed to evaluate mechanical performance.

Main Results:

  • Microscopy confirmed dimensional accuracy of printed discs.
  • Tensile strength ranged from 9-11 MPa, with comparable modulus values for three filaments.
  • All tested TPU filaments, when fabricated with gyroid structures, met target compression forces (4000-7500 N).

Conclusions:

  • All four thermoplastic polyurethane (TPU) filaments are suitable for fabricating intervertebral disc replacements.
  • The tested TPU materials and gyroid infill structures are viable for potential artificial disc applications.