3D Printing in Orthopaedic Implants: Design, Materials, Application

This chapter explores the impact made by 3D printing technology in the field of orthopaedic rehabilitation. It discusses the interdisciplinary needs in design and printing of implants, focusing on design principles, materials utilised and diverse applications within the field. Traditional manufacturing methods often constrain the complexity and customisation of implants, limiting their functionality and compatibility with patient anatomy. 3D printing technology offers the engineers design freedom, enabling them to create personalised implants tailored to individual patients. This chapter explains the design optimisation process, highlighting the use of finite element analysis (FEA) and computer-aided design (CAD) for biomechanically optimised implant design. The selection of materials for 3D-printed implants is explored, encompassing a range of biocompatible metallic alloys, biodegradable polymers, and ceramic materials that offer unique properties suited to specific applications. A case study of patient-specific implants that is enabled by 3D reconstruction and 3D printed patient-specific implants is discussed. The implants can be customised with porous structures and matt surface finish to promote osseointegration, as well as the integration of surgical guides and instruments for enhanced precision in orthopaedic surgeries. The chapter also discusses design procedures, software applications, and 3D printing methods involved in custom dental implant fabrication are explained in detail. The applications of 3D printing technology in orthopaedic implantology have undergone a fundamental change in patient care, offering remarkable levels of customisation, functionality, and biocompatibility. This chapter not only highlights the current state of the art but also casts an eye towards the horizon, where emerging technologies and materials could redefine what it means to receive an customised orthopaedic implant.