Fig 1.
Design workflow for patient-specific AM prosthesis for reconstruction of large bone defects after tumor resection including computed tomography (CT) of metal AM prosthesis.
Fig 2.
Patient’s data to design workflow; (A) patient’s MRI DICOM data, (B) reconstructed 3D anatomy of the proximal humerus with graded cross-section from distal to proximal aspect, and (C) designed patient-specific prosthesis. (D) Schematic diagram of the EBM process, and (E) final patient-specific AM prosthesis for tumor reconstruction.
Fig 3.
(A) Biomechanical testing (cyclic loading) of AM prosthesis for tumor reconstruction. (B-D) Applied boundary conditions in the FEA models; the grey region indicates where the stem (green) was fixed to a reference point at the bottom of the images; (B) S1 which mimics the previously established biomechanical test setup, and (C-D) S2 and S3 boundary conditions with applied multi—directional joint reaction forces [33] based on the previous in-vivo study.
Fig 4.
(A) Presence and distribution of trapped powder in porous regions of the prosthesis. In the CT images, trapped powders had halftone grayscale, which is between the melted powder and the void space (i.e., pore) grayscale values. Representative (B) all-in focus image showing the surface texture of the as-built EBM patient-specific prosthesis, and (C) associated height map.
Fig 5.
Cyclic loading results: (A) Displacement (of overall construct) vs number of cycles (shaded region represent variation in max and min of displacement at every cycle; and the solid red line is the mean displacement for every cycle), and (B) cyclic stiffness vs. number of cycles.
Fig 6.
FEA results: Von Mises stress (MPa) and maximum principal strain (absolute values) distributions across porous regions of the patient-specific AM prosthesis.
Table 1.
Morphological parameters at the porous regions of the prosthesis.
Table 2.
Measured roughness parameters, height surface roughness (ISO 25178) as well as amplitude-roughness (ISO 4287) after Gaussian filter with a cut-off value of 0.8 mm was applied.