Topology Optimization Additive Manufacturing-Oriented for a Biomedical Application

Topological optimization is a fairly innovative numerical technique that makes it possible to reduce the mass of mechanical components. It is an alternative to the optimizations of shape or geometry that allow to highly improve the efficiency of products. The recent development of metal additive manufacturing technologies allows the production of pieces that were not feasible before, permitting the use of topological optimization in many fields. In the biomedical field, for example, the reduction of prosthetic and orthotic materials allows to save weight, to the advantage of comfort, and to minimize the invasiveness of these systems. In this paper, an optimization of a system consisting of a femoral nail and two screws is carried out. The pieces were obtained by 3D scanning of prostheses, so as to obtain the true geometry. The femur is the standard one in literature. Following topological optimization, a new nail, with a mass of 60% of the previous one, was obtained, without limiting the functionality or the reliability of the product. Results and methodological problems are discussed.