Optimising bionic pore designs in a spiral blade implant to enhance bone ingrowth and stability: A combined CFD and large-animal study
Abstract
Purpose: This study aimed to evaluate the effects of different Bionic Pore geometries (circular, triangular, and rectangular) and diameters (0.8 mm, 1 mm, 2 mm, and 3 mm) on fluid shear stress (FSS) distribution and bone ingrowth in a bionic spiral blade implant.
Methods: Twelve Bionic Pore structures were modeled using CAD software, and computational fluid dynamics (CFD) analysis was performed to simulate the FSS distribution in a bone environment. Based on these simulation results, the circular hole design was selected and manufactured via electron beam melting (EBM). It was then incorporated into a bionic spiral blade (length: 50 mm, outer diameter: 6 mm, and a central canal of 2 mm for surgical pin placement). Four female sheep (weighing 35-40 kg) were implanted with these spiral blades, divided into 3-month and 6-month follow-up groups. After surgery, X-ray imaging, micro-CT, and histological evaluation were used to assess implant stability, bone bridging, and tissue response within the bionic pores.
Results: CFD simulations showed that circular pores generated a more optimal and uniform FSS distribution; the 0.8 mm circular pore produced an average FSS of 0.0086 ± 0.00013 Pa, representing a 79.1% and 68.0% reduction compared to identically sized triangular (0.0412 ± 0.0176 Pa) and rectangular pores (0.0269 ± 0.0056 Pa), respectively. In vivo experiments demonstrated that small-diameter holes significantly accelerated osteogenesis. At 3 months, the 0.8 mm group achieved…
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