Finite Element Evaluation of Biomimetic Porous Ti6Al4V Implants for Femoral Reconstruction: Mechanical Performance of Mono-Block and Modular Designs

Two design solutions such as modular and mono-block Ti6Al4V porous implants for femoral defect repair were implemented and compared. Static stress analysis on each model was performed via finite element analysis to investigate potential critical elements that might cause system failure under physiological loads. Prior to calculations, a mesh convergence study was realized by varying the minimum element sizes. The entire bone–prosthetic system was modeled, and design optimization was performed. For mono-block implants, a less stressed configuration was found by changing the plate design. Comparison of the maximum Von Mises stress σmax and equivalent strain εeq between the models allowed for an understanding of the distribution of the loads and identify areas with critical stress concentration. The modular implant appeared to be highly solicited with stress shielding on epiphyses due to enhanced rigidity at the metal/bone interface. Finally, a study of the deformation on cancellous and cortical bone suggested that a more elastic junction with balanced strain delivery to the bone might improve tissue regeneration when using a mono-block implant.