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Objective <p>This study aimed to develop a personalized tantalum-based three-column porous screw (TTCPS) using selective laser melting technology to improve the osseointegration, mechanical stability, and biocompatibility of fracture fixation screws with porous architecture.</p> Methods <p>TTCPS with an interconnected porous structure was customized through computer-aided design and fabricated using selective laser melting technique. Its mechanical properties were assessed via torsional resistance testing. Biocompatibility and osteogenic potential of TTCPS were evaluated on MC3T3-E1 cells by in vitro cell tests, including Live/Dead staining, scanning electron microscopy, alkaline phosphatase activity assays, and alizarin red staining. In vivo osseointegration capability of TTCPS was investigated using a comminuted fracture model in New Zealand white rabbits, with histological staining and mechanical pull-out tests that performed at 1, 2, and 3&#xa0;months post-surgery.</p> Results <p>TTCPS demonstrated a torsional resistance of 2.83 ± 0.07 N·m, which is comparable to conventional high-strength titanium-based alloys (P &gt; 0.05). In vitro experiments revealed high cell viability, pseudopod adhesion, and proliferation of MC3T3-E1 cells on TTCPS, alongside enhanced osteogenic differentiation and mineralization. In vivo studies showed progressive osseointegration, with pull-out forces of 123.6 ± 6.6 N, 370.6 ± 19.3 N, and 578.6 ± 21.3 N at 1, 2, and 3&#xa0;months post-surgery, respectively.</p> Conclusion <p>With its unique three-column structure, TTCPS improved primary stability and encouraged host bone ingrowth into its porous architecture, resulting in excellent osseointegration. This design overcomes clinical issues associated with traditional screws, such as screw fracture and bone defects. By integrating customized geometric optimization with biomimetic porous features, TTCPS provides a novel approach to fracture fixation, potentially transforming clinical management through enhanced biomechanical performance and biological integration.</p>

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Selective laser melted tantalum three-column porous screw: a novel design achieving both mechanical stability and biological fixation

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年7月27日

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  • Di Wu,
  • Zuofa Yan,
  • Bing Ge,
  • Yujin Dong,
  • Jiajun Zhao,
  • Bin Wu,
  • Fang Cao,
  • Haiyao Wang,
  • Zhijie Ma,
  • Junlei Li,
  • Dewei Zhao

摘要

Objective

This study aimed to develop a personalized tantalum-based three-column porous screw (TTCPS) using selective laser melting technology to improve the osseointegration, mechanical stability, and biocompatibility of fracture fixation screws with porous architecture.

Methods

TTCPS with an interconnected porous structure was customized through computer-aided design and fabricated using selective laser melting technique. Its mechanical properties were assessed via torsional resistance testing. Biocompatibility and osteogenic potential of TTCPS were evaluated on MC3T3-E1 cells by in vitro cell tests, including Live/Dead staining, scanning electron microscopy, alkaline phosphatase activity assays, and alizarin red staining. In vivo osseointegration capability of TTCPS was investigated using a comminuted fracture model in New Zealand white rabbits, with histological staining and mechanical pull-out tests that performed at 1, 2, and 3 months post-surgery.

Results

TTCPS demonstrated a torsional resistance of 2.83 ± 0.07 N·m, which is comparable to conventional high-strength titanium-based alloys (P > 0.05). In vitro experiments revealed high cell viability, pseudopod adhesion, and proliferation of MC3T3-E1 cells on TTCPS, alongside enhanced osteogenic differentiation and mineralization. In vivo studies showed progressive osseointegration, with pull-out forces of 123.6 ± 6.6 N, 370.6 ± 19.3 N, and 578.6 ± 21.3 N at 1, 2, and 3 months post-surgery, respectively.

Conclusion

With its unique three-column structure, TTCPS improved primary stability and encouraged host bone ingrowth into its porous architecture, resulting in excellent osseointegration. This design overcomes clinical issues associated with traditional screws, such as screw fracture and bone defects. By integrating customized geometric optimization with biomimetic porous features, TTCPS provides a novel approach to fracture fixation, potentially transforming clinical management through enhanced biomechanical performance and biological integration.