Computational biomechanical analysis of Ti-6Al-4V porous bone plates for lower limb fractures

The current study investigates the biomechanical performance of porous bone plates augmented with three different cellular lattice structures, e.g., body-centered cube (BCC), simple cube (SC), and the superposition of simple and body-centered cube (SC-BCC) structures. The SC-BCC cellular structures, exhibiting improved torsional, compression, and bending stiffness, were strategically integrated into the bone plates. Configurations ranging from one to three rows, with porosity ranging from 30% to 90%. Increasing the number of rows and porosity maximized the interfragmentary movement at the fracture site. Specifically, SC-BCC configurations with one, two and three rows at 90% porosity demonstrated callus volume improvements of 31.33%, 42%, and 43.2%, respectively, compared with the lowest callus volume observed with SC-BCC at one row and 30% porosity. Regardless of the improved volume, callus stiffness was highest at 30% and 90% porosity levels across all cases, indicating more mature tissue formation in calluses and better physiological load support. High stresses located at 90% porosity, followed by 50% porosity, discouraged their mechanical performance. Therefore, employing 30% porosity configurations with appropriate vertical rows for desired movement is recommended for optimal biomechanical performance. However, 90% porosity may be suitable in scenarios involving minimal forces and restricted patient movement.