Design and Manufacturing Process of 3D-Printed Metamaterial Calcaneal Plates via Scalar Field-Driven Porous Structure...

Area of Science:

• Biomaterials Engineering
• Orthopedic Surgery
• Additive Manufacturing

Background:

• Calcaneal fractures require advanced fixation devices.
• Existing bone plates may lack optimal mechanical and biofunctional integration.
• Metamaterials offer tunable properties for biomedical applications.

Purpose of the Study:

• To design and fabricate a metamaterial calcaneal bone plate with integrated mechanical and biofunctional properties.
• To investigate topology optimization and porous structure filling for enhanced plate performance.
• To evaluate the 3D-printed plate's fit, quality, and potential for clinical application.

Main Methods:

• Hybrid reverse-forward engineering for initial solid plate design.
• Topology optimization and scalar field-driven fusion for metamaterial structure creation.
• Direct 3D printing fabrication and postprocessing of the calcaneal bone plate.

Main Results:

• Topology-optimized plates showed uniform stress distribution and minimal displacement, ensuring safety and weight reduction.
• Kelvin cell and Diamond surface porous structures provided excellent filling, pore connectivity, and smooth transitions.
• The textured surface promoted cell adhesion, and 3D-printed plates exhibited high quality with a precise fit.

Conclusions:

• The developed metamaterial calcaneal bone plate demonstrates superior mechanical and biofunctional characteristics.
• 3D printing enables precise fabrication of complex metamaterial structures for orthopedic implants.
• This technology provides a strong foundation for the direct clinical application of advanced calcaneal bone plates.