Biomimetic and personalized optimization of additively manufactured metallic bone implants: Design, simulation, and clinical outcomes

Abstract

Additive manufacturing (AM) has transformed the field of metallic bone implants by enabling the production of patient-specific, biomimetic, and high-performance devices. This review focuses on the personalized design of bone implants using AM technologies, particularly selective laser melting and electron beam melting, which allow the fabrication of complex lattice structures that replicate the trabecular architecture of native bone. These architectures enhance load transfer, reduce stress shielding, and promote osseointegration. The review also explores current strategies and digital tools for biomimetic design, as well as numerical simulation methods—including finite element analysis, computational fluid dynamics, and multi-field coupling models—used to optimize implant geometry, porosity, and mechanical performance. Furthermore, recent clinical and preclinical data on in vivo functionality and biological integration are synthesized, with emphasis on the latest advancements to enhance functional outcomes. Altogether, the work provides a comprehensive roadmap for researchers and clinicians seeking to advance implant innovation and improve skeletal tissue repair.

Keywords

Additive manufacturing / Biomimetic implants / Electron beam melting / Lattice structures / Numerical simulation / Personalized bone implants / Selective laser melting

Funding

This work was supported by the Morocco–Switzerland bilateral program within the framework of the Memorandum of Understanding between the Ministry of Higher Education, Scientific Research and Innovation of the Kingdom of Morocco and the State Secretariat for Education, Research and Innovation of the Swiss Confederation.

Conflict of Interest

The authors declare no competing interests.

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