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<p>Patient-specific orthopedic implants fabricated using additive manufacturing have gained considerable attention because of their capability to improve anatomical conformity, fixation stability, and implant customization. However, systematic optimization of geometric design parameters for additively manufactured bone plates remains insufficiently investigated, particularly for Laser Powder Bed Fusion (LPBF)-fabricated Ti-6Al-4&#xa0;V implants subjected to standardized mechanical loading conditions. In the present study, a systematic geometric optimization and mechanical evaluation of anatomy-derived Ti-6Al-4&#xa0;V orthopedic fixation plates was performed using a Taguchi L9 design of experiments methodology. Three critical geometric parameters, namely plate length, width, and thickness, were investigated at three levels to evaluate their influence on bending stiffness and bending strength. Patient-specific plate geometries were generated using computed tomography (CT)-derived anatomical reconstruction and fabricated using LPBF technology. Mechanical characterization was conducted under ASTM F382-17 four-point bending conditions using quasi-static loading. Statistical analysis based on Analysis of Variance (ANOVA) and signal-to-noise ratio evaluation demonstrated that plate thickness was the most influential parameter governing both bending stiffness and bending strength, followed by plate width, whereas plate length exhibited comparatively lower influence on bending strength. The optimized geometric configurations demonstrated approximately 388% improvement in bending stiffness and nearly 198% improvement in bending strength compared with the lowest-performing experimental configuration (Run 7: 155&#xa0;mm length, 8&#xa0;mm width, and 3.0&#xa0;mm thickness) within the investigated design space, confirming thickness as the dominant structural reinforcement parameter. The results establish an experimentally validated framework for geometric screening and optimization of LPBF-fabricated Ti-6Al-4&#xa0;V fixation plates under ASTM F382-17 static bending conditions and demonstrate the capability of LPBF technology for manufacturing customized orthopedic implants with improved mechanical performance.</p>

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Experimental investigation of geometric parameters on the bending behavior of LPBF-fabricated Ti-6Al-4 V orthopedic fixation plates using Taguchi design methodology

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Gurtej Singh Kalsey,
  • Kanwaljit Singh Khas,
  • Abhishek Agarwal,
  • Hasddin

摘要

Patient-specific orthopedic implants fabricated using additive manufacturing have gained considerable attention because of their capability to improve anatomical conformity, fixation stability, and implant customization. However, systematic optimization of geometric design parameters for additively manufactured bone plates remains insufficiently investigated, particularly for Laser Powder Bed Fusion (LPBF)-fabricated Ti-6Al-4 V implants subjected to standardized mechanical loading conditions. In the present study, a systematic geometric optimization and mechanical evaluation of anatomy-derived Ti-6Al-4 V orthopedic fixation plates was performed using a Taguchi L9 design of experiments methodology. Three critical geometric parameters, namely plate length, width, and thickness, were investigated at three levels to evaluate their influence on bending stiffness and bending strength. Patient-specific plate geometries were generated using computed tomography (CT)-derived anatomical reconstruction and fabricated using LPBF technology. Mechanical characterization was conducted under ASTM F382-17 four-point bending conditions using quasi-static loading. Statistical analysis based on Analysis of Variance (ANOVA) and signal-to-noise ratio evaluation demonstrated that plate thickness was the most influential parameter governing both bending stiffness and bending strength, followed by plate width, whereas plate length exhibited comparatively lower influence on bending strength. The optimized geometric configurations demonstrated approximately 388% improvement in bending stiffness and nearly 198% improvement in bending strength compared with the lowest-performing experimental configuration (Run 7: 155 mm length, 8 mm width, and 3.0 mm thickness) within the investigated design space, confirming thickness as the dominant structural reinforcement parameter. The results establish an experimentally validated framework for geometric screening and optimization of LPBF-fabricated Ti-6Al-4 V fixation plates under ASTM F382-17 static bending conditions and demonstrate the capability of LPBF technology for manufacturing customized orthopedic implants with improved mechanical performance.