The modern approach to the recovery of damaged and missing bone tissue is increasingly focused on the application of implants capable of supporting the growth and recovery of parent tissue, rather than replacing the tissue itself. In this regard, the primary task of modern bone implants is to enable the targeted deformation of the implant against the expected load that that piece of bone should bear. The paper presents research related to anatomically shaped lattice scaffolds (ASLSs) made by the direct metal laser sintering (DMLS) of Ti-6Al-4V powder, and refers to the influence of the crossing angle between the outer lattice struts on the rigidity of the scaffold structure. The study includes the measurement of the deformation of two ASLSs designed for the same missing piece of rabbit tibia; these differed in terms of the crossing angle of the struts in the outer lattice and were exposed to quasi-uniaxial compression. The results show that the ASLS with outer struts that intersect at 60° (the angle between the compression direction and the strut axes is 30°) is more flexible compared to the ASLS with outer struts that intersect at 90° (the compression direction and the strut axes are colinear), even though its porosity is lower and volume is bigger.

This study investigates the elasticity of specific lattice structures made from titanium alloy (Ti6Al4V), namely, anatomically shaped lattice scaffolds (ASLS) aimed for reinforcement of the bone tissue graft that substitute a missing piece of the previously injured bone during its recovery. ASLSs that were used for testing were fabricated using the Electron Beam Melting (EBM) method. The mechanical properties of the ASLS were examined through uniaxial compression tests. Compression testing revealed the complex non-linear behavior of the scaffold structure’s elasticity, with distinct compression stages and deformation dependencies. The ASLS structures exhibited quasi-elastic deformation followed by the rupture of individual struts. Results demonstrate that the ASLSs can be stiffened by applying appropriate compression load and accordingly achieve the target elasticity of the structure for the specific load range. The modulus of elasticity was determined for different compression stages of ASLS, allowing interpolation of the functional relation between the modulus of elasticity and compressive force that is used for stiffening the ASLS. This study enhances the understanding of the mechanical behavior of the specific lattice structures made of Ti6Al4V and provides insights for the development of mechanically optimized anatomically shaped lattice scaffolds.

The paper reports on the importance of applying the holistic approach in designing a personalized bone scaffold, but also all other kinds of personalized implants. In addition, the paper attempts to point out the important aspects of the design of a PBS against which the quality of a realistic and applicable design solution should be assessed. The holistic approach refers to the adaptation of design features of a bone scaffold to the multilateral specifics related to the particular patient, its surgical case, and curing treatment. To ensure a successful application, five aspects of personalized bone scaffold design should be considered while it is being adapted: anatomical congruency, mechanical conformity, biochemical compatibility and biodegradability, manufacturability, and implantability. To demonstrate the importance of applying a holistic approach in designing a personalized bone scaffold, the paper shows a case where a patient-specific scaffold aimed at the reconstruction of a large missing piece of mandible was designed. The research resulted in a series of recommendations regarding the methods of bone geometry reconstruction and scaffold design. The paper sheds new light on the desired mechanical properties of a personalized bone scaffold while also recommending possible design parameters for optimizing the construction according to these properties. Finally, it recommends a possible procedure of integral production of personalized bone scaffold and bone graft. The presented so-called holistic approach announces a new systematic process of designing a personalized bone scaffold, which, although requiring a comprehensive consideration of complex requirements, is inevitable to make the designed solution applicable.

This study explores the potential benefits of the brick-layer deposition pattern in FDM 3D printing, focusing on its influence on inter-layer adhesion. Standard tensile test specimens conforming to the ISO 527-2/1B geometry were printed using a Bambu Lab X1 Carbon 3D printer with PLA filament. All printing parameters—such as layer height, speed, and temperature—were kept constant, with the only variables being the deposition pattern (conventional vs. brick-layer) and extrusion flow rate (default, +5%, and +10%). A total of six sets of specimens (five per set) were printed vertically to emphasize layer adhesion characteristics. Mechanical testing was conducted via uniaxial tensile testing to failure on universal testing machine. Preliminary results indicate improved performance in specimens printed using the brick-layer method, particularly when combined with increased flow rates. These findings suggest that the brick-layer strategy, though currently underutilized, holds promise for enhancing part strength in FDM printing—warranting further investigation.