Human bone inspired design of an Mg alloy-based foam

As an initial step of this research, open cell magnesium foams were obtained by infiltration casting using a preform of salt particles with irregular morphology. Despite this metallic foam was a successful approach to bone replacement scaffold, the properties of a metal foam need to be improved to meet the requirements by accurately adjusting the porous geometry. The tissue scaffold structure should be submissive biologically as well as mechanically and should at best mimic the natural properties of bone to act as an accurate bone substitute. The architectural and mechanical bone scaffold parameters determine the biological outcome. This work aims to design and manufacture an ordered foam with mechanical and architectural properties similar to those of the bone using an Mg alloy as a base material. Accordingly, representative features were identified to generate computer-aided designed (CAD) unit cells. Then, a set of the selected cells was assembled to obtain a specified architecture for bone replacement. Finite element method analysis was applied to calculate the mechanical response. The architectural parameters were varied to match the elastic properties of human bone concerning suitable exposed area, volume, and pore size. The best architecture was determined by compression loading acting on the assembly. Finally, polymeric stamps with sets of truncated octahedrons will be printed from the CAD model and were replicated in a clay made with a combination of salt and flour. Infiltration casting will obtain last of all, open cell magnesium foams.