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<p>Additive manufacturing of Ti-6Al-4V porous dental implants has become a prominent advancement in the field of prosthetic dentistry, providing enhanced osseointegration and biomechanical long-term stability. To further enhance the biomechanical properties, this study designed different porous structures with axial gradient porosity, investigated their stress distribution, and permeability behavior. The implant–bone mechanical interaction was studied using finite element analysis (FEA). To observe the actual mechanical performance and biological characteristics of implants, the experimental analysis was performed on the laser powder bed fusion LPBF-fabricated specimens together with cytocompatibility tests. The FEA results showed that a Gyroid structure with axial gradient porosity of 40–80% showed uniform stress distribution, and superior compression resistance, with ideal fluid permeability. The implant–bone interface simulations showed favorable von Mises stress–strain values of cortical bone around the porosity gradient Gyroid implant, within range (60 MPa stress, 100–3000 με strain), beneficial for bone ingrowth. Also, the Gyroid implant showed improved performance with reduced stress concentration and uniform stress distribution in cancellous bone as compared to the solid implant. The implant also demonstrated enhanced mechanical performance, with a compressive strength of 1241&#xa0;N, higher than maximum human bite forces. The implant’s tensile strength, insertion torque, and torque resistance reached 931.2&#xa0;N, 46&#xa0;N·cm, and 316&#xa0;N·cm, respectively. In vitro, cell experiments verified improved cell proliferation and differentiation, specifically in 60% porosity areas. These findings support potential clinical applications of the designed implant by confirming its biomechanical reliability and stability.</p>

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Laser powder bed fusion additive manufacturing of Ti-6Al-4V dental implants with gradient porosity: Design, simulation, and biomechanical performance

  • 期刊论文

  • 发表日期：

    2025年11月27日

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  • Syed Mesum Raza Naqvi,
  • Jiasen Gu,
  • Shuang Liu,
  • Chen Jiao,
  • Zhizhong Hua,
  • Kai Zhou,
  • Muhammad Ali Nasir,
  • Lin Wang,
  • Guofeng Wu,
  • Zongjun Tian,
  • Lida Shen

摘要

Additive manufacturing of Ti-6Al-4V porous dental implants has become a prominent advancement in the field of prosthetic dentistry, providing enhanced osseointegration and biomechanical long-term stability. To further enhance the biomechanical properties, this study designed different porous structures with axial gradient porosity, investigated their stress distribution, and permeability behavior. The implant–bone mechanical interaction was studied using finite element analysis (FEA). To observe the actual mechanical performance and biological characteristics of implants, the experimental analysis was performed on the laser powder bed fusion LPBF-fabricated specimens together with cytocompatibility tests. The FEA results showed that a Gyroid structure with axial gradient porosity of 40–80% showed uniform stress distribution, and superior compression resistance, with ideal fluid permeability. The implant–bone interface simulations showed favorable von Mises stress–strain values of cortical bone around the porosity gradient Gyroid implant, within range (60 MPa stress, 100–3000 με strain), beneficial for bone ingrowth. Also, the Gyroid implant showed improved performance with reduced stress concentration and uniform stress distribution in cancellous bone as compared to the solid implant. The implant also demonstrated enhanced mechanical performance, with a compressive strength of 1241 N, higher than maximum human bite forces. The implant’s tensile strength, insertion torque, and torque resistance reached 931.2 N, 46 N·cm, and 316 N·cm, respectively. In vitro, cell experiments verified improved cell proliferation and differentiation, specifically in 60% porosity areas. These findings support potential clinical applications of the designed implant by confirming its biomechanical reliability and stability.