Integrated FEA of a Generative Designed Prosthetic Hip Stem for Advanced Manufacturing

Abstract

This thesis, authored by Khaleel Abdullah Omar Alkhateib at the University of Debrecen (2026), investigates the integration of generative design (topology optimization) and Finite Element Analysis (FEA) to develop a structurally sound, mass-customizable prosthetic hip stem for additive manufacturing. The primary biomechanical challenge addressed is stress shielding; a phenomenon where overly stiff metallic implants absorb mechanical load from surrounding bone, causing bone resorption and implant loosening over time. Using in-vivo telemetry data from the OrthoLoad database, the study derived realistic physiological loads for three patient profiles and applied them across both static and dynamic FEA simulations. The generative internal channel network not only reduces stem stiffness to better match natural bone but also promotes bone ingrowth (osseointegration), which is a physiological advantage over conventional solid stems. Finally, a comparative manufacturing feasibility assessment concluded that Direct Metal Laser Sintering (DMLS) via the EOS M290 is the superior production method, as 5-axis CNC machining is physically incapable of reproducing the complex internal geometries required by the generative design.