Evaluation of the stiffness characteristics of square pore CoCrMo cellular structures manufactured using laser melting technology for potential orthopaedic applications

In order to improve the stress shielding characteristics of orthopaedic devices implants that mimic the mechanical behaviour of bone need to be considered. Additive layer manufacturing processes provide a capability to produce orthopaedic implants with tailored mechanical properties. In this work cobalt chrome molybdenum cellular structures have been designed and manufactured using selective laser melting, with volume based porosity ranging between 25% and 95%. The effective mechanical properties have been determined through uniaxial compression testing and compared to numerical and analytical predictions where differences were observed. Cellular structures have been presented that exhibit similar stiffness and strength characteristics when compared to cortical and cancellous bone in the human femur. An expression has been proposed to predict the effective elastic modulus of cobalt chrome molybdenum cellular structures with volumetric porosity of 65% and above. A finite element modelling technique has been used to demonstrate that structural variation and heterogeneities that are associated with the manufacture of cellular structures can significantly decrease the effective stiffness.