Design and Mechanical Compatibility of Nylon Bionic Cancellous Bone Fabricated by Selective Laser Sintering

In order to avoid the stress shielding phenomenon in orthopedic bionic bone implantation, it is necessary to consider the design of mechanical compatible implants imitating the host bone. In this study, we developed a novel cancellous bone structure design method aimed at ensuring the mechanical compatibility between the bionic bone and human bone by means of computer-aided design (CAD) and finite element analysis technology (specifically, finite element modeling (FEM)). An orthogonal lattice model with volume porosity between 59% and 96% was developed by means of CAD. The effective equivalent elastic modulus of a honeycomb structure with square holes was studied by FEM simulation. With the purpose of verifying the validity of the cancellous bone structure design method, the honeycomb structure was fabricated by selective laser sintering (SLS) and the actual equivalent elastic modulus of the honeycomb structure was measured with a uniaxial compression test. The experimental results were compared with the FEM values and the predicted values. The results showed that the stiffness values of the designed structures were within the acceptable range of human cancellous bone of 50–500 MPa, which was similar to the stiffness values of human vertebrae L1 and L5. From the point of view of mechanical strength, the established cellular model can effectively match the elastic modulus of human vertebrae cancellous bone. The functional relationship between the volume porosity of the nylon square-pore honeycomb structure ranging from 59% to 96% and the effective elastic modulus was established. The effect of structural changes related to the manufacture of honeycomb structures on the equivalent elastic modulus of honeycomb structures was studied quantitatively by finite element modeling.