The influence of geometric defects and microstructure in the simulation of the mechanical behaviour of laser powder-bed fusion components: Application to endoprosthesis

This work aims at enabling the fabrication of a new generation of prosthetic components with enhanced mechanical behaviour and an extended lifetime. Cobalt-chromium lattice structures manufactured using laser powder bed fusion are analysed to quantify the influence of microstructural anisotropy and geometrical deviations on stiffness prediction. Results of the experimental campaign are used to improve finite-element modelling of the mechanical behaviour of functionally graded lattice structures. The proposed method, which can be extended to any lattice structure fabricated by laser powder bed fusion, is then used to redesign an ankle prosthetic component.