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The mismatch between stiffness of the femoral dense stem and host bone causes complications to patients, such as aseptic loosening and bone resorption. Three‐dimensional finite‐element models of homogeneous porous (HGP) and functionally graded porous (FGP) stems incorporating body‐centered cubic (BCC) structures are proposed in this article as an alternative to the dense stems. The relationship between the porosity and strut thickness of the BCC structure was developed to construct the finite‐element models. Three levels of porosities (20%, 50%, and 80%) were modeled in HGP and FGP stems. The porosity of the stems was decreased distally according to the sigmoid function (n = 0.1, n = 1 and n = 10) with 3 grading exponents. The results showed that FGP stems transferred 120%‐170% higher stresses to the femur (Gruen zone 7) as compared to the solid stem. Conversely, the stresses in HGP and FGP stems were 12%‐34% lower than the dense stem. The highest micromotions (105‐147 µm) were observed for stems of 80% overall porosity, and the lowest (42‐46 µm) was for stems of 20% overall porosity. Finally, FGP stems with a grading exponent of n = 10 resulted in an 11%‐28% reduction in micromotions.

The current study is proposing a design envelope for porous Ti-6Al-4V alloy femoral stems to survive under fatigue loads. Numerical computational analysis of these stems with a body-centered-cube (BCC) structure is conducted in ABAQUS. Femoral stems without shell and with various outer dense shell thicknesses (0.5, 1.0, 1.5, and 2 mm) and inner cores (porosities of 90, 77, 63, 47, 30, and 18%) are analyzed. A design space (envelope) is derived by using stem stiffnesses close to that of the femur bone, maximum fatigue stresses of 0.3σys in the porous part, and endurance limits of the dense part of the stems. The Soderberg approach is successfully employed to compute the factor of safety Nf > 1.1. Fully porous stems without dense shells are concluded to fail under fatigue load. It is thus safe to use the porous stems with a shell thickness of 1.5 and 2 mm for all porosities (18–90%), 1 mm shell with 18 and 30% porosities, and 0.5 mm shell with 18% porosity. The reduction in stress shielding was achieved by 28%. Porous stems incorporated BCC structures with dense shells and beads were successfully printed.

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In bone tissue engineering, multifunctional composite materials are very challenging. Bone tissue engineering is an innovative technique to develop biocompatible scaffolds with suitable orthopedic applications with enhanced antibacterial and mechanical properties. This research introduces a polymeric nanocomposite scaffold based on arabinoxylan- co -acrylic acid, nano-hydroxyapatite (nHAp), nano-aluminum oxide (nAl 2 O 3 ), and graphene oxide (GO) by free-radical polymerization for the development of porous scaffolds using the freeze-drying technique. These polymeric nanocomposite scaffolds were coated with silver (Ag) nanoparticles to improve antibacterial activities. Together, nHAp, nAl 2 O 3 , and GO enhance the multifunctional properties of materials, which regulate their physicochemical and biomechanical properties. Results revealed that the Ag-coated polymeric nanocomposite scaffolds had excellent antibacterial properties and better microstructural properties. Regulated morphological properties and maximal antibacterial inhibition zones were found in the porous scaffolds with the increasing amount of GO. Moreover, the nanosystem and the polymeric matrix have improved the compressive strength (18.89 MPa) and Young’s modulus (198.61 MPa) of scaffolds upon increasing the amount of GO. The biological activities of the scaffolds were investigated against the mouse preosteoblast cell lines (MC3T3-E1) and increasing the quantities of GO helps cell adherence and proliferation. Therefore, our findings showed that these silver-coated polymeric nanocomposite scaffolds have the potential for engineering bone tissue.