Mechanical and Structural Evaluation of an Additively Printed Gyroid Lattice Structure of a CoCr Alloy

Abstract

This Master thesis explores gyroid lattice structures—a type of Triply Periodic Minimal Surface (TPMS)—made from CoCr-0404 alloy for medical implants, combining lightweight design with high strength using AM (SLM). Three gyroid designs (2-cell, 3-cell, and 4-cell) were 3D-printed and tested for hardness, compression strength, and surface quality. The 2-cell structure showed the best mechanical performance (489 HV hardness, 90–95 MPa compressive strength), making it suitable for load-bearing applications, while the 4-cell design offered better surface uniformity and pore connectivity, which are crucial for bone integration. Post-processing, like tumbling, improved surface smoothness by up to 30.8%, enhancing biocompatibility. The study highlights how TPMS-based gyroids can revolutionize orthopedic implants by balancing strength and bio functionality through customizable designs. Future research could focus on real-world performance under dynamic loads and long-term in vivo testing to further validate their clinical potential.