Bone remodeling in additive manufactured porous implants changes the stress distribution

Safety and efficacy of additive manufactured porous implants is a growing concern due to several, recent recalls. The safety of bone implants depends on the effects of implantation and partial bone ingrowth on stress and strain. Finite element analysis, using two new algorithms to simulate bone ingrowth, was verified against histology results for an ovine condylar critical sized defect model. Implants were manufactured from Ti6Al4V using selective laser sintering. Results showed that partial bone formation reduces stress concentrations to safe levels, improving the long-term fatigue resistance. Higher bone ingrowth was predicted for implants made from lower modulus Titanium-tantalum alloy.