Generation of Customized Bone Implants from CT Scans Using FEA and AM

Claude Wolf*, Deborah Juchem*, Anna Koster, Wilfrid Pilloy

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

Abstract

Additive manufacturing (AM) allows the creation of customized designs for various medical devices, such as implants, casts, and splints. Amongst other AM technologies, fused filament fabrication (FFF) facilitates the production of intricate geometries that are often unattainable through conventional methods like subtractive manufacturing. This study aimed to develop a methodology for substituting a pathological talus bone with a personalized one created using additive manufacturing. The process involved generating a numerical parametric solid model of the specific anatomical region using computed tomography (CT) scans of the corresponding healthy organ from the patient. The healthy talus served as a mirrored template to replace the defective one. Structural simulation of the model through finite element analysis (FEA) helped compare and select different materials to identify the most suitable one for the replacement bone. The implant was then produced using FFF technology. The developed procedure yielded commendable results. The models maintained high geometric accuracy, while significantly reducing the computational time. PEEK emerged as the optimal material for bone replacement among the considered options and several specimens of talus were successfully printed.

Original languageEnglish
Article number4241
JournalMaterials
Volume17
Issue number17
DOIs
Publication statusPublished - Sept 2024
Externally publishedYes

Keywords

  • CT segmentation
  • FEA
  • additive manufacturing
  • biomaterials
  • fused filament fabrication
  • implant
  • patient’s specific
  • simulation

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