Porous biomaterials are often used to treat large bony defects or fractured vertebras. Most of such biomaterials are made of metals and their alloys and have a pre-defined, fixed shape. Due to their predefined fixed shape, however, they are not suitable for implantation through minimally invasive surgical procedures. To overcome this problem, we designed three different deployable non-assembly mechanisms, which were manufactured using selective laser melting. These deployable geometries, including a bicapped cube, a bicapped trigonal antiprism, and a bicapped square antiprism, possess a large aspect ratio in their retracted state. Upon the application of an external force, they expand radially into their deployed load-bearing configuration. Using non-assembly manufacturing, revolute joints, wavelike elements, rigid rods and restrictions could be integrated into the design. The designs were manufactured in such a way that the least amount of support structures was required during the fabrication process. Additionally, the deployable structures were functional immediately after printing. Mechanical tests were performed to determine the forces required to deploy the designed structures and to determine their failure load. A maximum change of 322 ± 7% in the circumdiameter was found for the bicapped trigonal antiprism while the bicapped square antiprism showed the largest reduction in the height (61 ± 1%). A maximum force of 10.3 ± 1.6 N was required during the deployment process of the bicapped square antiprism 3. The bicapped antiprisms could support up to 1212 ± 45.5 N before they failed, while the bicapped cubes failed under a force of 232 ± 5.5 N. The elongated geometry of our designs makes them ideal for implantation using minimally invasive surgical procedures. Given the fact that these are the first non-assembly deployable bone substitutes manufactured using selective laser melting, further studies are required to make them suitable as orthopedic implants.

多孔生物材料通常用于治疗大的骨缺损或椎骨骨折。大多数此类生物材料由金属及其合金制成，并具有预先定义的固定形状。然而，由于它们预定义的固定形状，它们不适合通过微创外科手术进行植入。为了克服这个问题，我们设计了三种不同的可展开非组装机构，它们是使用选择性激光熔化制造的。这些可展开的几何形状，包括双端立方体、双端三角反棱镜和双端方形反棱镜，在其收缩状态下具有大的纵横比。在施加外力时，它们会径向扩展到展开的承重配置。采用非组装制造，旋转接头，波浪形元件，刚性杆和限制可以集成到设计中。这些设计的制造方式使得在制造过程中需要最少的支撑结构。此外，可展开结构在打印后立即起作用。进行机械测试以确定展开设计结构所需的力并确定其失效载荷。发现双端三角反棱镜的圆周直径变化最大为 322 ± 7%，而双端方形反棱镜的高度减小幅度最大 (61 ± 1%)。在双端方形反棱镜 3 的部署过程中，需要的最大力为 10.3 ± 1.6 N。 双端反棱镜在失效前可以支持高达 1212 ± 45.5 N 的力，而双端立方体在 232 ± 5.5 N 的力下失效。我们设计的细长几何形状使其非常适合使用微创外科手术进行植入。鉴于这些是第一个使用选择性激光熔化制造的非组装可部署骨替代品，需要进一步研究以使其适合作为骨科植入物。