Fabrication and Numerical Analysis of Non-Metallic Orthopedic Prostheses Using Ultrasound Techniques for Reducing Infection in Sports-Related Injuries

Abstract

Joint replacement has garnered considerable attention as a medical intervention for addressing sports-related joint injuries, offering the potential to restore sports activities and enhance quality of life. However, prioritizing safety measures and injury prevention during exercise is crucial. The increasing prevalence of infections in knee arthroplasty surgeries is a significant concern for both patients and surgeons, emphasizing the necessity for implants with proven efficacy against periprosthetic joint infections (PJI). In this study, two samples were prepared: sample 1 comprised pure copper nanoparticles, while sample 2 consisted of copper nanoparticles supplemented with titanium nanoparticles (TiNP) using the powder metallurgy (PM) technique. The copper prosthesis was characterized using X-ray diffraction (XRD), scanning electron microscope (SEM), and compressive strength tests. The biological behavior of the samples was evaluated in simulated body fluid (SBF) and phosphate buffer saline (PBS) over 3 months. The results demonstrated that the fabricated copper prosthesis exhibited a mesoporous microstructure, with a specific surface area ranging from 150 to 200 (cm2/g). The samples displayed porosity levels of 25 % to 32 %, with pore volumes ranging from 50 to 100 nm. The addition of TiNP to the copper nanoparticles reduced the specific surface area and pore volume of the prosthesis. Cell viability and electrical conductivity assessments revealed the formation of a thin apatite layer on the surface of the copper sample with added titanium nanoparticles. This study leverages the unique capabilities of ultrasound technology to fabricate and evaluate the performance of these novel prosthetic components. The inclusion of TiNP decreased the dissolution rate and increased apatite formation. Moreover, the mechanical properties of the prosthesis improved, and its biological behavior was enhanced, resulting in the development of a beam-shaped biological implant that was analytically analyzed. The addition of approximately 10 wt% TiNP was found to be effective in improving the mechanical and biological properties of the copper-titanium implant. © 2025 The Author(s).