Novel “load adaptive algorithm based” procedure for 3D printing of cancellous bone-inspired structures

This work shows the practical application and the experimental validation of a procedure based on an algorithm, running in a finite element environment, able to operate inside a convex three-dimensional solid by replacing the continuous mass with an appropriate cancellous bone-inspired space frame sharing, with the solid, the border and organized for having the fibres oriented according to the boundary conditions. The purpose is to reach the maximum mechanical efficiency realizing a load adaptive space frame optimized in terms of weight. Young's moduli of a cubic virtual specimen were numerically estimated. Fifteen specimens were printed by a 3D printer using a titanium alloy. Numerical results were compared with experimental ones obtained by tensile tests. The simulation results confirmed the validity of the FEM “beam element-based” space frame.