Optimizing a Design for Additive Manufacturing: A Case Study on Total Knee Replacement Prostheses

Additive Manufacturing (AM) offers transformative potential in orthopedic implant design, providing opportunities for customization, complexity, and patient-specific solutions. The present project investigates the optimization of a total knee replacement (TKR) prosthesis design for metal AM, focusing on the Renishaw AM 400 machine. Utilizing medical imaging data from MRI and CT scans and employing 3D Slicer, Solidworks, and ANSYS Workbench, we aim to develop a TKR design that maximizes the advantages of AM. The study explores the integration of topology optimization to enhance the implant's mechanical performance while minimizing material usage. Compared to traditional manufacturing methods, a comprehensive economic analysis is conducted to assess the cost-effectiveness of producing the optimized implant using a Renishaw AM 400 system. Our findings will contribute to the advancement of AM in orthopedic applications, providing insights into the feasibility of patient-specific 3D-printed knee implants. The results have implications for medical device and orthopedic stakeholders, guiding the adoption of AM technologies in improving TKR design outcomes while maintaining cost-effectiveness and sustainability. In closing, the project showcases innovative approaches in additive manufacturing for medical applications.