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REVIEW ARTICLE

Biomimetic and personalized optimization of additively manufactured metallic bone implants: Design, simulation, and clinical outcomes

Lamiae Jaouher1 ,  Abdelwahed Barkaoui1,2* ,  Khalil Aouadi3 ,  Haifa Sallem4
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1 LERMA Lab, International University of Rabat, Parc Technopolis, Rocade de Rabat-Sale, Morocco
2 LMAI Lab, Ecole Nationale d’Ingénieurs de Tunis, Université de Tunis El Manar, Tunisia
3 Engineering and Durability of Materials Center, Moroccan Foundation for Advanced Science, Innovation & Research (MAScIR), Mohammed VI Polytechnic University, Hay Moulay Rachid, Ben Guerir, Morocco
4 Institute of Systems Engineering (HEI), HES-SO Valais-Wallis, University of Applied Sciences and Arts Western Switzerland (HES-SO), Sion, Switzerland
IJB, 025270261 https://doi.org/10.36922/IJB025270261
Received: 1 July 2025 | Accepted: 6 August 2025 | Published online: 25 August 2025
(This article belongs to the Special Issue 3D Printing for Advancing Orthopedic Applications)
© 2025 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
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Abstract

Additive manufacturing (AM) has transformed the field of metallic bone implants by enabling the production of patient-specific, biomimetic, and high-performance devices. This review focuses on the personalized design of bone implants using AM technologies, particularly selective laser melting and electron beam melting, which allow the fabrication of complex lattice structures that replicate the trabecular architecture of native bone. These architectures enhance load transfer, reduce stress shielding, and promote osseointegration. The review also explores current strategies and digital tools for biomimetic design, as well as numerical simulation methods—including finite element analysis, computational fluid dynamics, and multi-field coupling models—used to optimize implant geometry, porosity, and mechanical performance. Furthermore, recent clinical and preclinical data on in vivo functionality and biological integration are synthesized, with emphasis on the latest advancements to enhance functional outcomes. Altogether, the work provides a comprehensive roadmap for researchers and clinicians seeking to advance implant innovation and improve skeletal tissue repair.

Graphical abstract
Keywords
Additive manufacturing
Biomimetic implants
Electron beam melting
Lattice structures
Numerical simulation
Personalized bone implants
Selective laser melting
Funding
This work was supported by the Morocco–Switzerland bilateral program within the framework of the Memorandum of Understanding between the Ministry of Higher Education, Scientific Research and Innovation of the Kingdom of Morocco and the State Secretariat for Education, Research and Innovation of the Swiss Confederation.
Conflict of interest
The authors declare no competing interests.
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International Journal of Bioprinting, Electronic ISSN: 2424-8002 Print ISSN: 2424-7723, Published by AccScience Publishing
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