Experimental Evaluation of the Effects of Discrete-Grading-Induced Discontinuities on the Material Properties of Functionally Graded Ti-6Al-4V Lattices.

In this study, we compared the material properties of linearly and sharply graded Ti6Al4V additively manufactured samples to investigate whether the more severe discontinuities caused by sharp grading can reduce performance. We performed compression testing with digital image correlation (DIC) in two loading directions for each grading design to simulate iso-stress and iso-strain conditions. We extracted the elastic stiffness, yield strength, yield strain, and energy absorption capacity of each sample. In addition, we used micro-computed tomography (micro-CT) imaging to examine the printing quality and dimensional accuracy. We found that sharply graded struts have a 12.95% increase in strut cross-sectional areas, whereas linearly graded struts produced an average of 49.24% increase compared to design. However, sharply graded and linearly graded FGL samples do not have statistically significant differences in elastic stiffness and yield strength. For the iso-strain condition, the average DIC-corrected stiffnesses for linearly and sharply graded samples were 6.15 GPa and 5.43 GPa, respectively (p = 0.4466), and the yield stresses were 290.4 MPa and 291.2 MPa, respectively (p = 0.5734). Furthermore, we confirmed different types of printing defects using micro-CT, including defective pores and disconnected struts. These results suggest that the loss of material properties caused by manufacturing defects outweighs the adverse effects of discrete-grading-induced discontinuities.

Stress-shielding resistant design of custom pelvic prostheses using lattice-based topology optimization.

Endoprosthetic reconstruction of the pelvic bone using 3D-printed, custom-made implants has delivered early load-bearing ability and good functional outcomes in the short term to individuals with pelvic sarcoma. However, excessive stress-shielding and subsequent resorption of peri­prosthetic bone can imperil the long-term stability of such implants. To evaluate the stress-shielding performance of pelvic prostheses, we developed a sequential modeling scheme using subject-specific finite element models of the pelvic bone-implant complex and personalized neuromusculoskeletal models for pre- and post-surgery walking. A new topology optimization approach is introduced for the stress-shielding resistant (SSR) design of custom pelvic prostheses, which uses 3D-printable porous lattice structures. The SSR optimization was applied to a typical pelvic prosthesis to reconstruct a type II+III bone resection. The stress-shielding performance of the optimized implant based on the SSR approach was compared against the conventional optimization. The volume of the peri­prosthetic bone predicted to undergo resorption post-surgery decreased from 44 to 18%. This improvement in stress-shielding resistance was achieved without compromising the structural integrity of the prosthesis. The SSR design approach has the potential to improve the long-term stability of custom-made pelvic prostheses.

Finite element analysis of screw fixation durability under multiple boundary and loading conditions for a custom pelvic implant.

Despite showing promising functional outcomes for pelvic reconstruction after sarcoma resection, custom-made pelvic implants continue to exhibit high complication rates due to fixation failures. Patient-specific finite element models have been utilized by researchers to evaluate implant durability. However, the effect of assumed boundary and loading conditions on failure analysis results of fixation screws remains unknown. In this study, the postoperative stress distributions in the fixation screws of a state-of-the-art custom-made pelvic implant were simulated, and the risk of failure was estimated under various combinations of two bone-implant interaction models (tied vs. frictional contact) and four load cases from level-ground walking and stair activities. The study found that the average weighted peak von Mises stress could increase by 22-fold when the bone-implant interactions were modeled with a frictional contact model instead of a tied model, and the likelihood of fatigue and pullout failure for each screw could change dramatically when different combinations of boundary and loading conditions were used. The inclusion of additional boundary and loading conditions led to a more reliable analysis of fixation durability. These findings demonstrated the importance of simulating multiple boundary conditions and load cases for comprehensive implant design evaluation using finite element analysis.

A computational method for estimating trunk muscle activations during gait using lower extremity muscle synergies.

One of the surgical treatments for pelvic sarcoma is the restoration of hip function with a custom pelvic prosthesis after cancerous tumor removal. The orthopedic oncologist and orthopedic implant company must make numerous often subjective decisions regarding the design of the pelvic surgery and custom pelvic prosthesis. Using personalized musculoskeletal computer models to predict post-surgery walking function and custom pelvic prosthesis loading is an emerging method for making surgical and custom prosthesis design decisions in a more objective manner. Such predictions would necessitate the estimation of forces generated by muscles spanning the lower trunk and all joints of the lower extremities. However, estimating trunk and leg muscle forces simultaneously during walking based on electromyography (EMG) data remains challenging due to the limited number of EMG channels typically used for measurement of leg muscle activity. This study developed a computational method for estimating unmeasured trunk muscle activations during walking using lower extremity muscle synergies. To facilitate the calibration of an EMG-driven model and the estimation of leg muscle activations, EMG data were collected from each leg. Using non-negative matrix factorization, muscle synergies were extracted from activations of leg muscles. On the basis of previous studies, it was hypothesized that the time-varying synergy activations were shared between the trunk and leg muscles. The synergy weights required to reconstruct the trunk muscle activations were determined through optimization. The accuracy of the synergy-based method was dependent on the number of synergies and optimization formulation. With seven synergies and an increased level of activation minimization, the estimated activations of the erector spinae were strongly correlated with their measured activity. This study created a custom full-body model by combining two existing musculoskeletal models. The model was further modified and heavily personalized to represent various aspects of the pelvic sarcoma patient, all of which contributed to the estimation of trunk muscle activations. This proposed method can facilitate the prediction of post-surgery walking function and pelvic prosthesis loading, as well as provide objective evaluations for surgical and prosthesis design decisions.

Bilateral asymmetry of bone density adjacent to pelvic sarcomas: A retrospective study using computed tomography.

Limb-salvaging hemipelvectomy surgeries involving allograft or custom prosthesis reconstruction require high quality remaining pelvic bone for adequate device fixation. Modeling studies of custom pelvis prosthesis designs typically mirror contralateral pelvic bone material properties to the ipsilateral pelvis. However, the extent of bone material property and geometric symmetry, and thus the appropriateness of mirroring, remains unknown and should be considered when designing or analyzing the performance of pelvic prostheses. This study investigates preoperative differences between ipsilateral and contralateral pelvic bone for patients with a pelvic sarcoma. Computed tomography (CT) data were obtained retrospectively from eight patients with a pelvic sarcoma. Subject-specific computational models of the pelvic bones were constructed from the CT data. Bilateral asymmetry of bone material properties and cross-sectional areas between the ipsilateral and contralateral hemipelvis were quantified at points adjacent to the pelvic sarcoma. Large bilateral asymmetry (>20%) in trabecular but not cortical bone density was observed within 20 mm of the tumor location. Differences in trabecular bone density typically declined with increased distance from the tumor. The greatest bilateral difference in cross-sectional area occurred within 10 mm of the tumor boundary for three patients and within 40 mm from the tumor site for four patients. Our results suggest that pelvic sarcomas can cause significant bilateral asymmetries in trabecular bone density for patients with a pelvic sarcoma. These differences should be taken into account when designing custom implants for this patient population.

Heterogeneous material mapping methods for patient-specific finite element models of pelvic trabecular bone: A convergence study.

Patient-specific finite element (FE) models of bone require the assignment of heterogeneous material properties extracted from the subject's computed tomography (CT) images. Though node-based (NB) and element-based (EB) material mapping methods (MMMs) have been proposed, the sensitivity and convergence of FE models to MMM for varying mesh sizes are not well understood. In this work, CT-derived and synthetic bone material data were used to evaluate the effect of MMM on results from FE analyses. Pelvic trabecular bone data was extracted from CT images of six subjects, while synthetic data were created to resemble trabecular bone properties. The numerical convergence of FE bone models using different MMMs were evaluated for strain energy, von-Mises stress, and strain. NB and EB MMMs both demonstrated good convergence regarding total strain energy, with the EB method having a slight edge over the NB. However, at the local level (e.g., maximum stress and strain), FE results were sensitive to the field type, MMM, and the FE mesh size. The EB method exhibited superior performance in finer meshes relative to the voxel size. The NB method converged better than did the EB method for coarser meshes. These findings may lead to higher-fidelity patient-specific FE bone models.