Hybrid solid mesh structure for electron beam melting customized implant to treat bone cancer

15Bone replacement implants manufactured by electron beam melting have been widely studied for use in bone tumor treatment. In this application, a hybrid structure implant with a combination of solid and lattice structures guarantees strong adhesion between bone and soft tissues. This hybrid implant must exhibit adequate mechanical performance so as to satisfy the safety criteria considering repeated weight loading during the patient’s lifetime. With a low volume of a clinical case, various shape and volume combinations, including both solid and lattice structures, should be evaluated to provide guidelines for implant design. This study examined the mechanical performance of the hybrid lattice by investigating two shapes of the hybrid implant and volume fractions of the solid and lattice structures, along with microstructural, mechanical, and computational analyses. These results demonstrate how hybrid implants may be designed to improve clinical outcomes by using patient-specific orthopedic implants with optimized volume fraction of the lattice structure, allowing for effective enhancement of mechanical performance as well as optimized design for bone cell ingrowth.