Topology and Lattice-Based Structural Design Optimization for Additively Manufactured Medical Implants

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Topology-based optimization techniques and lattice structures are powerful ways to accomplish lightweight components with enhanced mechanical performance. Recent developments in additive manufacturing (AM) have led the way to extraordinary opportunities in realizing complex designs that are derived from topology and lattice-based structural optimization. The main aim of this work is to give a contribution, in the integration between structural optimization techniques and AM, by proposing a setup of a proper methodology for rapid development of optimized medical implants addressing oseeointegration and minimization of stress shielding related problems. The validity of the proposed methodology for a proof of concept was demonstrated ... continued below

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Peto, Marinela May 2019.

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  • Peto, Marinela

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Description

Topology-based optimization techniques and lattice structures are powerful ways to accomplish lightweight components with enhanced mechanical performance. Recent developments in additive manufacturing (AM) have led the way to extraordinary opportunities in realizing complex designs that are derived from topology and lattice-based structural optimization. The main aim of this work is to give a contribution, in the integration between structural optimization techniques and AM, by proposing a setup of a proper methodology for rapid development of optimized medical implants addressing oseeointegration and minimization of stress shielding related problems. The validity of the proposed methodology for a proof of concept was demonstrated in two real-world case studies: a tibia intramedullary implant and a shoulder hemi prosthetics for two bone cancer patients. The optimization was achieved using topology optimization and replacement of solid volumes by lattice structures. Samples of three lattice unit cell configurations were designed, fabricated, mechanically tested, and compared to select the most proper configuration for the shoulder hemi prosthesis. Weight reductions of 30% and 15% were achieved from the optimization of the initial design of the tibia intramedullary implant and the shoulder hemiprosthesis respectively compared to initial designs. Prototypes were fabricated using selective laser melting (SLM) and direct light processing (DLP) technologies. Validation analysis was performed using finite element analysis and compressive mechanical testing. Future work recommendations are provided for further development and improvement of the work presented in this thesis.

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  • May 2019

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  • June 9, 2019, 9:09 p.m.

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Peto, Marinela. Topology and Lattice-Based Structural Design Optimization for Additively Manufactured Medical Implants, thesis, May 2019; Denton, Texas. (https://digital.library.unt.edu/ark:/67531/metadc1505245/: accessed August 17, 2019), University of North Texas Libraries, Digital Library, https://digital.library.unt.edu; .