Mechanical Analysis and Simulation of 3D‐Printed Femur Segments With Biomimetic Porosity

Three‐dimensional (3D) printing has transformed medical engineering by enabling customized bone prostheses. This study designs and evaluates a 3D‐printed femur segment with manually crafted porosity mimicking natural bone tissue. Mechanical performance is assessed through compression testing, dynamic simulation, fatigue analysis, and crack propagation. Compression tests yielded average fracture force of 9.456 kN, stress of 11.76 MPa, strain of 8.68 mm, and energy of 42.6 kJ. The biomimetic porosity showed superior resistance compared to alternatives. Fatigue simulations indicated infinite life under in vivo loads. Crack simulations at failure sites showed stresses of 12.82 and 11.89 MPa. Findings highlight biomimetic designs′ potential in bone tissue engineering.