Design and Analysis Frameworks for Additively Manufactured Orthopaedic Implants: A Review of Lattice Architectures and Finite Element Approaches

Abstract

Additive manufacturing (AM) has emerged as a transformative approach in orthopaedic implant design by enabling the fabrication of patient-specific geometries and complex internal architectures. This paper presents a comprehensive review of design frameworks and analytical methodologies used in the development of additively manufactured orthopaedic implants, with particular emphasis on lattice structures and finite element analysis (FEA). The study outlines the complete workflow from medical imaging and computer-aided design to fabrication and post-processing, highlighting key considerations in implant design such as anatomical conformity, fixation strategies, and material selection. The role of lattice and porous architectures in tailoring mechanical properties and promoting osseointegration is critically examined, with attention to design parameters including pore size, strut thickness, and relative density. Furthermore, commonly adopted finite element modelling approaches are analysed to evaluate stress distribution, deformation, and micromotion under physiological loading conditions. The review also discusses challenges related to process variability, modelling assumptions, and the absence of standardized validation frameworks. Emerging trends, including the integration of optimization techniques and artificial intelligence, are explored as potential solutions to improve design efficiency and predictive accuracy. The findings indicate that the effective combination of advanced design strategies, computational modelling, and additive manufacturing technologies can significantly enhance implant performance and reliability. This study provides a structured perspective on current developments and future directions in the field of additively manufactured orthopaedic implants.