The acetabular cups used in total hip arthroplasty are mostly made of dense metal materials with an elastic moduli much higher than that of human bone. This leads to stress shielding after implantation, which may cause aseptic loosening of the implant. Selective laser melting (SLM) technology allows us to produce tiny and complex porous structures and to reduce the elastic moduli of dense metals, thereby avoiding stress shielding. In the present study, rhombic dodecahedron porous structures with cell sizes of 1 mm, 1.5 mm, and 2 mm were designed. The strut diameter was changed to ensure that the porosity and pore size would meet the bone ingrowth requirements. Then, porous Ti6Al4V alloy specimens were printed using SLM, and compressive tests were carried out. The results showed that the compressive strength and elastic modulus values of the specimens with a cell size of 1.5 mm were in the range of 78.16–242.94 MPa and 1.74–4.17 GPa, respectively, which are in line with the mechanical properties of human cortical bone. Finite element analysis of a total hip joint model was carried out to simulate gait, and the surface of the trabecular acetabular cup was divided into 10 regions according to the stress distribution, with the stress interval in the range of 37.44–219.24 MPa. According to the compression test results, the gradient structure of Ti6Al4V alloy with different porosity was designed for trabecular coating. The gradient porous structure meets the mechanical requirements and is closer to the natural structure of human bone than the uniformly distributed porous structure.

The elastic modulus of traditional solid titanium alloy tibial implants is much higher than that of human bones, which can cause stress shielding. Designing them as a porous structure to form a bone-like trabecular structure effectively reduces stress shielding. However, the actual loading conditions of bones in different parts of the human body have not been considered for some trabecular structures, and their mechanical properties have not been considered concerning the personalized differences of other patients. Therefore, based on the elastic modulus of the tibial stem obtained from Quantitative Computed Tomography (QCT) imaging between 3.031 and10.528 GPa, and the load-bearing state of the tibia at the knee joint, a porous structure was designed under compressive and shear loading modes using topology optimization. Through comprehensive analysis of the mechanical and permeability properties of the porous structure, the results show that the Topology Optimization–Shear-2 (TO-S2) structure has the best compressive, shear mechanical properties and permeability and is suitable as a trabecular structure for tibial implants. The Gibson–Ashby model was established to control the mechanical properties of porous titanium alloy. A gradient filling of porous titanium alloy with a strut diameter of 0.106–0.202 mm was performed on the tibial stem based on the elastic modulus range, achieving precise matching of the mechanical properties of tibial implants and closer to the natural structure than uniformly distributed porous structures in human bones. Finally, the new tibial implant was printed by selective laser melting (SLM), and the molding effect was excellent.