Computational biomechanical analysis of Ti-6Al-4V porous bone plates for lower limb fractures.

[Display omitted] • Porous bone plates with cubic (C), diamond (BCC) and body-centered cubic (CBCC) structures were prepared. • Axial compression, torsional and bending tests were carried out to check the designs' reliability. • CBCC structure with enhanced performance was used with varying rows' and porosities. • Finite element analysis was used to check the biomechanical performance of bone plates. • Increased porosity enhanced the callus volume but displayed poor mechanical performance. The current study investigates the biomechanical performance of porous bone plates augmented with three different cellular lattice structures, e.g., body-centered cube (BCC), simple cube (SC), and the superposition of simple and body-centered cube (SC-BCC) structures. The SC-BCC cellular structures, exhibiting improved torsional, compression, and bending stiffness, were strategically integrated into the bone plates. Configurations ranging from one to three rows, with porosity ranging from 30% to 90%. Increasing the number of rows and porosity maximized the interfragmentary movement at the fracture site. Specifically, SC-BCC configurations with one, two and three rows at 90% porosity demonstrated callus volume improvements of 31.33%, 42%, and 43.2%, respectively, compared with the lowest callus volume observed with SC-BCC at one row and 30% porosity. Regardless of the improved volume, callus stiffness was highest at 30% and 90% porosity levels across all cases, indicating more mature tissue formation in calluses and better physiological load support. High stresses located at 90% porosity, followed by 50% porosity, discouraged their mechanical performance. Therefore, employing 30% porosity configurations with appropriate vertical rows for desired movement is recommended for optimal biomechanical performance. However, 90% porosity may be suitable in scenarios involving minimal forces and restricted patient movement. [ABSTRACT FROM AUTHOR]