Background: This study aims to design, analyze and manufacture lightweight hip implants which have sufficient fatigue performance to enable use in total hip arthroplasty (THA). Methods: The lattice structure was applied on an implant geometry, which is frequently used in THA, to provide a reduction in mass and increase flexibility. The implant surfaces were roughened using semispherical pores to improve the osseointegration. The specimens were manufactured by means of direct metal laser sintering (DMLS) and fatigue tests were performed according to ISO 7206-4:2010. Moreover, fatigue analyses of the designed implants were numerically carried out using the finite element method. Results: The applied lattice structure on implant geometry leads to 15–17% reduction in the masses of implants compared to a solid one. It has also been determined that the lightweight implants show more flexible behavior with increasing pore diameter used on the implant surfaces while keeping the lattice structure geometry constant. The fatigue test and finite element analysis (FEA) results are in reasonable agreement. In addition, additively manufactured solid implants have exhibited similar fatigue performance with one produced by conventional methods. Conclusions: This paper presents design, analysis, manufacturing and fatigue test processes of lightweight hip implants. The lattice structure and the semispherical pores were applied on a reference implant geometry and they were manufactured by DMLS. The fatigue tests and FEA were performed to evaluate newly designed implant performance. All the implants successfully completed the fatigue tests without any damage.

中文翻译：

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轻型髋关节植入物的设计、制造和疲劳分析

背景：本研究旨在设计、分析和制造轻质髋关节植入物，这些植入物具有足够的疲劳性能，可用于全髋关节置换术 (THA)。方法：将晶格结构应用于 THA 中常用的种植体几何形状，以减轻质量并增加灵活性。使用半球形孔粗化植入物表面以改善骨整合。试样通过直接金属激光烧结 (DMLS) 制造，并根据 ISO 7206-4:2010 进行疲劳测试。此外，使用有限元方法对设计的植入物进行了数值分析。结果：与实心相比，在种植体几何形状上应用的晶格结构导致种植体质量减少 15-17%。还已经确定，随着在植入物表面上使用的孔径增加，轻质植入物表现出更灵活的行为，同时保持晶格结构几何形状不变。疲劳试验和有限元分析 (FEA) 结果相当一致。此外，增材制造的固体植入物表现出与传统方法生产的植入物相似的疲劳性能。结论：本文介绍了轻型髋关节植入物的设计、分析、制造和疲劳测试过程。晶格结构和半球形孔应用于参考植入物几何形状，它们由 DMLS 制造。进行疲劳测试和 FEA 以评估新设计的植入物性能。所有的植入物都顺利完成了疲劳测试，没有任何损坏。