Design and development of TI-6AL-4V femoral component for knee joint by direct metal laser sintering (DMLS)

Total knee arthroplasty (TKA) is a widely performed surgical procedure that relies on the mechanical integrity and biocompatibility of the femoral component to ensure long-term success. The selection of an optimal biomaterial remains a critical challenge, as existing materials exhibit trade-offs between mechanical strength, wear resistance, and costeffectiveness. This study investigates the mechanical performance of Ti-6Al-4V and Stainless Steel L316 (SS L316) as femoral component materials under incremental and cyclic loading conditions, addressing a key research gap in the comparative evaluation of these materials through both simulation and experimental validation. Finite Element Analysis (FEA) was conducted in ANSYS to predict total deformation, equivalent stress, principle stress, and shear stress under varying loading conditions. Experimentally, femoral components were fabricated using Direct Metal Laser Sintering (DMLS) 3D printing, followed by heat treatment, electrical discharge machining (EDM) for post-processing, and ultrasonic cleaning to enhance surface finish and mechanical properties. The results indicate that Ti-6Al-4V exhibits superior stability under cyclic loading, while SS L316 experiences slightly higher stress variations but maintains comparable deformation behavior, making it a viable alternative for cost-sensitive applications with enhanced corrosion resistance. The novelty of this research lies in the integrated simulation-experimental approach to assessing femoral components under realistic biomechanical conditions, providing critical insights into material selection for next-generation orthopedic implants. The findings contribute to optimizing TKA implant performance, reducing failure rates, and enhancing patient outcomes, thereby bridging the gap between computational modeling and real-world applications.