Design and manufacturing process research of 3D-printed field-driven metamaterial pelvic bone plate
To address the inherent limitations of conventional pelvic bone plates, including poor anatomical matching, unsatisfactory mechanical performance, excessive weight, and inadequate biocompatibility, this study aims to develop a personalized pelvic bone plate by integrating field-driven metamaterial design with three-dimensional (3D) printing. The methodology involves computed tomography (CT) imaging and Mimics software for reconstruction of the pelvic model, finite element simulation for topology optimization, and 3D printing for direct fabrication of the designed plate. The results demonstrate that the bone plate reconstructed from the pelvic fracture surface exhibits high anatomical fit. After topology optimization, the deformation of the bone plate increases by approximately 15%, accompanied by uniform stress distribution without obvious stress concentration. For the field-driven porous bone plate, the relative density of the porous structure increases with increasing local stress. The partially porous bone plate achieves a 30.77 % weight reduction while combining the favorable mechanical properties of solid plates with the biological potential of porous architectures. The 3D-printed personalized bone plate exhibits excellent forming quality, surface finish, and assembly fit. This study demonstrates the feasibility of the proposed structural design and 3D printing process, providing theoretical support and technical references for the subsequent development of high-performance personalized pelvic bone plates.
