Topology Optimization of a Patient-Specific Femoral Component for Total Knee Endoprosthesis

Abstract

This study presents a computational framework for the topology optimization of a patient-specific femoral component used in the total knee endoprosthesis. The motivation stems from the growing need to enhance implant longevity and biomechanical compatibility by optimizing internal structural design according to physiological loading conditions. A finite element–based density optimization method was employed to determine the optimal material distribution within the femoral component while maintaining anatomical geometry and functional constraints. The model was developed using realistic boundary conditions derived from knee joint mechanics, and the resulting design was compared with a conventional reference geometry. The optimized configuration exhibited more uniform stress distribution, reduced peak von Mises stresses, and improved mass efficiency without compromising mechanical stiffness. These findings demonstrate that the proposed method can significantly improve the structural performance and reliability of knee prostheses. The study concludes that integrating patient-specific modeling with topology optimization offers a promising pathway for developing advanced, individualized orthopedic implants and supports future experimental validation through 3D printing and biomechanical testing.