Optimal design of customised hip prosthesis using fiber reinforced polymer composites

The need for new materials in orthopaedic surgery arises from the recognition of the stress-shielding effect of bone by high-modulus implants presently made of engineering alloys. A lower modulus implant material will result in the construction of a more biomechanically compatible prosthesis. In this respect, composite materials are gaining importance because they offer the potential for implants with tailor-made stiffness in contrast to metals. In the present study, the bending stiffness of composite prosthesis is matched with that of bone in both the longitudinal and radial directions by choosing optimal carbon fiber reinforced polyether ether ketone (PEEK) matrix lay-up. A numerical optimization algorithm is developed to deduce the optimal composite femoral prosthesis lay-up that matches the stiffness properties of the femoral bone in both the transverse and longitudinal directions. Effective bending moments and compressive forces acting on the hip joint are considered in the design of the optimal length and diameter of the prosthesis. The optimization algorithm was implemented, by using MATLAB(R)™ for designing the composite prosthesis to a patient's specific requirement. Finally the efficiency of the composite stem is compared with that of metallic alloy stems in terms of stress shielding using a finite element program.