Design and Manufacturability of Compliant and Anatomically Optimized Spinal Implants Using Laser Powder Bed Fusion Additive Manufacturing

Description

This presentation from the ISTA 2024 conference held in Nashville, highlights the advancements in the design and manufacturability of compliant, anatomically optimized spinal implants. The speaker opens with an introduction, noting the significance of being included in this inaugural women in arthroplasty technology session. After troubleshooting technical difficulties, they delve into their research involving metal additive manufacturing, which shows potential for enhancing osseointegration and compliance in orthopedic implants, particularly spinal implants.



The speaker discusses challenges in manufacturing lattice and porous structures due to issues with unsupported downward-facing surfaces. They present findings from their research group that establishes a connection between lattice design, mechanical performance, and manufacturability. The objective is to create spinal implants with tailored lattice structures optimized for compliance and anatomical fit through a digital workflow that integrates design tools.



In their study, three types of implant fill designs—traditional solid cages, gyroid lattices, and Voronoi lattices—are examined, with a focus on matching the mechanical properties of human vertebral end plates. The presentation includes details on the evaluation of implant designs through a digital printability workflow, discussing techniques for assessing manufacturability via CAD analysis, 3D printing in titanium, and quantifying defects using X-ray computed tomography.



The results reveal high manufacturability of the implants, with a focus on maintaining a discrete downward surface area ratio below 1, critical for ensuring effective manufacturing. The presentation concludes with a discussion on the cost implications of additive manufacturing for patient-specific implants, including considerations of performance longevity versus traditional manufacturing costs. The speaker engages with questions from the audience, addressing issues such as mechanical testing and the significance of pore sizes in bone ingrowth, while also acknowledging future research directions in enhancing implant designs in conjunction with the ongoing advancements in additive manufacturing technologies.

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