Detailed design for additive manufacturing and post processing of generatively designed high tibial osteotomy fixation plates

Abstract Integration of advanced technologies have revitalised treatment methods in the current clinical practice. In orthopaedic surgery, patient-specific implants leveraged design freedom offered by additive manufacturing (AM) exploiting capabilities within powder bed fusion processes. Furthermore, generative (GD), a exploration tool based on artificial intelligence, can integrate constraints concept development phase, consequently bridging gap between AM and manufacturing. However, reproducibility implant prototypes are severely constrained due to uncomprehensive information post processing techniques detailed phase. This paper explores feasibility novel GD plate designs for High Tibial Osteotomy (HTO), joint preserving surgery patient diagnosed with osteoarthritis knee. A (DfAM) workflow generatively designed HTO is presented, including; DfAM designs, fabrication using electron beam (PBF-EB) medical grade Ti-6Al-4 V, inspection. The study established PBF-EB as suitable method highly complex fixations, through evaluating impact surface finish geometrical precision features.