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In this study, porous scaffolds for orthopedic implants made of Ti6Al4V material are
investigated with respect to their structural and mechanical optimization. The suitability of
these lattice structures for osseointegration and load-bearing applications was evaluated by
finite element analysis (FEA) with porosities of 23% to 89%. The mechanical properties,
such as Young's modulus and yield strength, were assessed to align with cortical and
trabecular bone requirements. 11 out of 24 scaffold configurations were found to meet
mechanical criteria for bone compatibility. These include IsoTruss, Re-Entrant, BCC, and
Diamond unit cells with particular configurations and porosities ranging from 54% to 85%.
Trabecular bone properties were mimicked by scaffolds with high porosities while the
cortical bone properties were mimicked by scaffolds with high densities. Sensitivity
analysis revealed that Re-Entrant scaffolds were the most sensitive to strut thickness and
unit cell volume variations, and IsoTruss and Re-Entrant scaffolds were found to be highly
mechanically efficient. The structural performance of the scaffolds was also validated
against the Gibson–Ashby model. This work thus demonstrates the capability of porous
Ti6Al4V scaffolds to fulfill requirements for orthopedic implant technology between
mechanical performance and biological compatibility.