Finite Element Analysis of Renewable Porous Bones and Optimization of Additive Manufacturing Processes

Three-dimensional printing technology has a precise manufacturing process that can control tiny pores and can design individualized prostheses based on the patient’s own conditions. Different porous structures were designed by controlling different parameters such as porosity, using UG NX to establish models with different porosities and using ANSYS to simulate stress and strain. Unidirectional compression and stretching simulations were carried out to obtain stress, strain, and deformation. Based on these data, a porosity was found to approximate the elastic modulus of the humeral bone scaffold. As the porosity increased, the equivalent elastic modulus decreased significantly in the lateral direction, and the maximum stress formed by the porous structure and deformation increased significantly. Four different finite element models and geometric models of cubic, face-centered cubic, honeycomb, and body-centered cubic unit structures were selected. Then these porous structures were simulated for tensile and compression experiments, and the simulation results were analyzed. The forming simulation of the finite element model was carried out, and the evolution of mechanical properties of the porous structure during the 3D printing process was analyzed. The results showed that designing the humeral bone scaffold as a porous structure could reduce the stiffness of the prosthesis, alleviate stress shielding around the prosthesis after surgery, enhance its stability, and prolong its service life. The study provides reference values and scientific guidance for the feasibility of porous humeral bone scaffolds and provides a basis for the research and design of clinical humeral bone scaffolds.