Design for Additive Manufacturing and Finite Element Analysis of Fe-Mn Biodegradable Fracture Fixation Plate with Varying Porosity Levels

Shaikh, Mustafiz; Kahwash, Fadi; Lu, Zhilun; Alkhreisat, Mohammad; Shyha, Islam

Abstract

Fracture fixation plates are osteosynthesis implants used to fix fractured bones in a human body. They are either left in the body or required to be removed after a bone healing period of 3–6 months. Recent trends focus on developing iron (Fe) based porous biodegradable implants eliminating the need for revision surgery. However, Fe alloys in their porous state are prone to a higher rate of corrosion resulting in detrimental mechanical properties. This study proposes a design strategy to develop fracture fixation implants mimicking natural cortical bone, i.e., targeting to possess enough structural strength with a minimal level of porosity. Three fixation plates each with 5, 10, and 15% porosity are developed having a gyroid lattice structure of Triply Periodic Minimal Surface designs. Four-point bending simulation is performed on Ansys to characterize the mechanical properties of the designed implants. Results show a decreasing trend of bending strength and flexural stiffness with higher porosity, but still relevant for fixation of fractured sites at different regions. The bending properties of developed implants are compared with USFDA’s proposed performance criteria, which shows 5% porous implants capable of all load-bearing extremities, whereas implants having 10 and 15% porosity are deemed to be suitable for tibia and humerus fixation.

Citation

Shaikh, M., Kahwash, F., Lu, Z., Alkhreisat, M., & Shyha, I. (2023, September). Design for Additive Manufacturing and Finite Element Analysis of Fe-Mn Biodegradable Fracture Fixation Plate with Varying Porosity Levels. Presented at International Conference on Additive Manufacturing in Products and Applications 2023, Zurich, Switzerland

• Presentation Conference Type: Conference Paper (published)
• Conference Name: International Conference on Additive Manufacturing in Products and Applications 2023
• Start Date: Sep 12, 2023
• End Date: Sep 14, 2023
• Acceptance Date: Sep 1, 2023
• Online Publication Date: Sep 12, 2023
• Publication Date: 2024
• Deposit Date: Jan 19, 2024
• Publicly Available Date: Sep 13, 2024
• Publisher: Springer
• Pages: 239-254
• Series Title: Springer Tracts in Additive Manufacturing
• Series ISSN: 2730-9576
• Book Title: Industrializing Additive Manufacturing: Proceedings of AMPA2023
• ISBN: 9783031429828, 9783031429859
• DOI: https://doi.org/10.1007/978-3-031-42983-5_17
• Keywords: Fracture fixation plate, Design for additive manufacturing, Four-point bending test simulation, Metal additive manufacturing, Triply periodic minimal surface design, Porous implant
• Public URL: http://researchrepository.napier.ac.uk/Output/3487441
• Related Public URLs: https://ampa.ethz.ch/