Mitigating Stress Shielding in Dorr C Femurs via Additive Manufacturing: A Proof-of-Concept Numerical Analysis

Bone resorption secondary to stress shielding is a leading cause of hip implant failure, primarily due to the stiffness mismatch between the femur and the prosthesis. Although anatomical stem designs generally provide improved load transfer, Dorr type C femurs often require straight stems to ensure adequate primary stability. This work presents a systematic approach to designing a straight, additively manufactured porous titanium hip stem aimed at minimizing stress shielding. The lattice architecture is customized to replicate the mechanical properties of bone based on patient-specific femoral CT scans. The performance of the resulting porous implant is numerically assessed under simplified physiological gait loading conditions. The implant behavior is evaluated through a homogenization strategy to model the lattice structure, significantly reducing the computational effort and making the methodology easily replicable. Compared to its full counterpart, the porous design achieves a significant reduction in predicted bone loss, suggesting that the proposed framework is a promising proof of concept for patient-specific implants. While further experimental validation and larger cohort studies are required, these findings highlight the potential of mechanically tunable porous structures to mitigate the stress shielding phenomenon in anatomical conditions such as Dorr type C femurs, which require straight stems.