Structural design strategies for additively manufactured customized implants: manufacturing technologies and clinical applications
Year: 2026
Type: article
Abstract: Bone defect repair remains a significant challenge in clinical orthopedics. Traditional bone grafting has limitations, including limited donor material, donor-site complications, and the risk of immune rejection. Moreover, achieving compatibility with a patient’s bone is difficult, which hinders clinical outcomes. To address these issues, customized implants created with computer-aided design and advanced manufacturing techniques such as 3D printing offer patient-customized solutions. In this review, we outline the principles and clinical uses of advanced manufacturing, focusing on material extrusion, direct ink writing, and 4D printing, and highlight their advantages for customized implants. Furthermore, the role of engineered porous structures – pillar-based, TPMS, and functionally graded designs – in optimizing implant performance is described. We also examine how artificial intelligence supports implant design and review the current clinical status of customized implants. Finally, we summarize the challenges of high equipment and material costs and complex regulatory procedures.
Authors: Mingshang Chao, Huan Hu, David Hui, Yun Zhai
Institutions: Dalian Jiaotong University, LSU New Orleans
Language: English
Subfield: Biomedical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $1,469
OpenAlex ID: W7204546952