Customized Design Optimization & Additive Manufacturing for Revision Arthroplasty

Total hip replacement is one of the most successful surgeries performed in orthopedics. It is an effective procedure that can cure hips that have been damaged by arthritis, a fracture, or other conditions e.g. Accidents, Injuries. High Impact Exercises, etc. It usually lasts longer, however, a hip replacement can fail for a variety of reasons. In that case, a doctor often recommends another operation; It involves generally acetabular cup revision. Therefore, the demand of acetabular cup revision typically increases with the increase in total hip arthroplasty. The poster presents a study on the use of generative design and additive manufacturing for custom acetabular cup revisions. Acetabular cup revisions are surgeries to replace the acetabular cup, which is the cup-shaped part of the hip implant. These surgeries can be complex and challenging. The study used Autodesk Fusion 360 to design acetabular cup revisions using generative design. The results showed that generative design can lead to a 30-40% reduction in the mass of the acetabular cup. The lightweight acetabular cups also showed more flexible behavior and almost similar fatigue performance. The generative design and additive manufacturing have the potential to improve the outcome of acetabular cup revisions. However, we acknowledge that more research is needed to validate their findings in clinical trials.