Every year, almost 4 million patients received medical care for knee osteoarthritis. Osteoarthritis involves progressive deterioration or degenerative changes in the cartilage, leading to inflammation and pain as the bones and ligaments are affected. To enhance treatment and surgical outcomes, various studies analyzing the biomechanics of the human skeletal system by fabricating simulated bones, particularly those reflecting the characteristics of patients with knee osteoarthritis, are underway. In this study, we fabricated replicated bones that mirror the bone characteristics of patients with knee osteoarthritis and developed a skeletal model that mimics the actual movement of the knee. To create patient-specific replicated bones, models were extracted from computerized tomography (CT) scans of knee osteoarthritis patients. Utilizing 3D printing technology, we replicated the femur and tibia, which bear the weight of the body and support movement, and manufactured cartilage capable of absorbing and dispersing the impact of knee joint loads using flexible polymers. Furthermore, to implement knee movement in the skeletal model, we developed artificial muscles based on shape memory alloys (SMAs) and used them to mimic the rolling, sliding, and spinning motions of knee flexion. The knee movement was investigated by changing the SMA spring’s position, the number of coils, and the applied voltage. Additionally, we developed a knee-joint-mimicking system to analyze the movement of the femur. The proposed artificial-skeletal-model-based knee-joint-mimicking system appears to be applicable for analyzing skeletal models of knee patients and developing surgical simulation equipment for artificial joint replacement surgery.

The surge in demand for patient-specific orthopedic implants necessitates the precise optimization of design and processing parameters for artificial trabecular bone. This research utilizes Voronoi-based porous structures to replicate the irregular geometry characteristic of natural trabecular bone. All specimens were fabricated through fused deposition modeling (FDM) with polylactic acid (PLA). The study systematically investigated the influence of four primary parameters, namely build orientation, extruder temperature, layer height, and pore count, on compressive strength. To ensure experimental efficiency, the research implemented a Taguchi L20 orthogonal array. Subsequent signal-to-noise (S/N) ratio analysis identified the optimal parameter set as a y-90° build orientation, an extruder temperature of 200 °C, a layer height of 0.2 mm, and a count of 150 pores. These findings underscore the necessity of integrated geometric and process parameter optimization to advance additive manufacturing for orthopedic applications.

Knee osteoarthritis (OA), also known as degenerative arthritis, is a disease characterized by irreversible changes in the cartilage and bones comprising the joints, resulting in pain, impaired function, and deformity. Furthermore, independent of natural aging, the rate of change in joint cartilage has increased in recent years, which is mainly attributed to environmental factors. The rising incidence of knee-related disorders emphasizes the importance of analyzing the morphology and kinematics of knee structure. This study introduces a knee measurement system designed to replicate the motions of knee using 3D-printing technology, providing insights into knee mechanics with OA level. The research explores the stages of OA using the Kellgren–Lawrence (KL) grade scale, highlighting the variations in the force applied to the knee bone according to movement. The developed knee-simulation system, utilizing the four-bar-link theory, presents a novel approach to studying OA levels 0 to 4. As OA progresses, the cartilage deteriorates, affecting the movement of OA. The OA-based knee measurement system that incorporates soft tissues and skeletons can assist in developing a personalized diagnostic approach for knee disease. This will also help to enhance surgical effectiveness by facilitating the creation of personalized prosthetic joints for individual patients and offering a customized surgical simulation.