Technical Summary

The aim of this research is to benchmark the mechanical performance of spinal cage implants fabricated using two distinct additive manufacturing (AM) techniques: Laser Powder Bed Fusion (PBF-LB) and a novel Screw-Based Material Extrusion (SBME) method, applied to Ti-6Al-4V and bioresorbable magnesium (Mg) alloys. The core technical challenge lies in understanding how processing parameters, microstructure, porosity, and lattice architecture influence critical mechanical properties such as compressive strength, fatigue life, and elastic modulus—particularly in bioresorbable materials which degrade over time.

 What makes this work novel is its direct comparison between a well-established, high-temperature metal AM process and a low-temperature extrusion-based technique for Mg alloys—materials that are difficult to process due to their reactive nature and degradation behaviour. The research incorporates finite element analysis (FEA) validated by experimental testing on synthetic vertebrae, adding a computational layer to the mechanical benchmarking. In parallel, the study explores how sensor data and microstructural features can be correlated to optimize AM parameters, pushing the boundaries of process control and implant design.

 This research is exciting because it addresses a gap in the development of next-generation spinal implants, combining advanced manufacturing, bioresorbable materials, and biomechanical engineering to deliver high-performance, patient-specific solutions. It offers the potential to reshape clinical approaches to spinal repair while contributing to the broader field of medical device innovation.