Special Issue Article Proc IMechE Part H: J Engineering in Medicine 2017, Vol. 231(6) 525–533 Ó IMechE 2017 Reprints and permissions: sagepub.co.uk/journalsPermissions.nav DOI: 10.1177/0954411917692009 journals.sagepub.com/home/pih Development of finite element model for customized prostheses design for patient with pelvic bone tumor Taimoor Iqbal 1 , Lei Shi 2 , Ling Wang 1 , Yaxiong Liu 1 , Dichen Li 1 , Mian Qin 1 and Zhongmin Jin 1,3 Abstract The aim of this study was to design a hemi-pelvic prosthesis for a patient affected by pelvic sarcoma. To investigate the biomechanical functionality of the pelvis reconstructed with designed custom-made prosthesis, a patient-specific finite element model of whole pelvis with primary ligaments inclusive was constructed based on the computed tomography images of the patient. Then, a finite element analysis was performed to calculate and compare the stress distribution between the normal and implanted pelvis models when undergoing three different static conditions—both-leg standing, single-leg standing for the healthy and the affected one. No significant differences were observed in the stresses between the normal and reconstructed pelvis for both-leg standing, but 20%–40% larger stresses were predicted for the peak stress of the single-leg standing (affected side). Moreover, two- to threefold of peak stresses were predicted within the prostheses compared to that of the normal pelvis especially for single-leg standing case, however, still below the allow- able fatigue limitation. The study on the load transmission functionalityof prosthesis indicated that it is crucial to carry out finite element analysis for functional evaluation of the designed customized prostheses before three-dimensional printing manufacturing, allowing better understanding of the possible peak stresses within the bone as well as the implants for safety precaution. The finite element model can be equally applicable to other bone tumor model for bio- mechanical studying. Keywords Customized hemi-pelvic endoprosthesis, finite element analysis, biomechanics, pelvic tumor, three-dimensional printing manufacturing Date received: 18 April 2016; accepted: 12 January 2017 Introduction The human pelvis is a complex geometric structure, which forms upper part of the hip and transmits upper body load to the lower limb. 1,2 The pelvis can be dam- aged due to accidents or pelvic bone tumors, 2 which usually involve large area of tissue removal and greatly affect the quality of patient’s lives. 3 Due to the complex anatomical structure, pelvic resection and reconstruc- tion is still a challenge. Metallic prostheses, such as tita- nium- or cobalt-base alloy, are also most commonly used to reconstruct the function of pelvis because of their availability, modularity, immediate fixation and relatively low rates of complication. 4,5 But the draw- backs are aseptic loosening, infection and peripros- thetic fracture. 6,7 These drawbacks may be results of the material’s microstructure, 8 lack of design 9–11 and the methods of fixation. 12 Along with the requirements of surgical techniques, there is a need for precise design to reduce the fracture risks, earlier restoration of func- tion and long durability of the prosthesis. Implantation of a prosthesis after hemi-pelvic resec- tion often leads to a high complication rate and low functional results. 13 Conventional methods such as 1 State Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, China 2 Department of Orthopedics, Xijing Hospital, The Fourth Military Medical University, Xi’an, China 3 Institute of Medical and Biological Engineering, School of Mechanical Engineering, University of Leeds, Leeds, UK Corresponding author: Ling Wang, State Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi 710054, China. Email: menlwang@mail.xjtu.edu.cn