Finite Element and Computational Fluid Dynamics Analysis of a Biodegradable Implant for Large Femoral Bone Defects

The treatment of large bone defects represents a major clinical challenge. Biodegradable metallic 3D-printed scaffolds are promising for orthopedic applications due to their ability to provide sufficient mechanical support while gradually degrading and supporting bone healing. This study investigates the mechanical and fluid transport properties of Fe-10Mn-1Pd scaffolds for femoral fracture repair. The performance of 10 different lattice structures was first evaluated using finite element modeling (FEM) and validated by experimental compression testing, identifying the parallel face-centered cubic (PFCC) scaffold as optimal due to its superior stiffness-to-weight ratio. The selected PFCC scaffold was then geometrically optimized, integrated with a biodegradable ZK60 magnesium plate-screw system, and analyzed under walking cycle loading using FEM and computational fluid dynamics (CFD), which demonstrated uniform stress distribution, minimal stress shielding, and an average wall shear stress of 0.7 Pa, favorable for osteogenesis and fluid transport. These findings confirm that the PFCC Fe-10Mn-1Pd scaffold, combined with a magnesium-based fixation mechanism, provides both mechanical support and fluid transmission.