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Design, FEA and experimental validation of 3D-printed PLA/PCL intervertebral cages for lumbar spinal fusion

  • Meltem Eryildiz

    Dr. Meltem Eryildiz, born in 1987, is an Associate Professor of Mechanical Engineering at Istanbul Beykent University, Turkey, specializing in additive manufacturing and polymer composites.

     ORCID logo EMAIL logo     , Ozge Altintas Kadirhan

    Dr. Ozge Altintas Kadirhan, an Associate Professor of Neurology at Kırklareli University Faculty of Medicine, focuses on vascular neurology and neuroprotective treatments.

     ORCID logo     , Mehmet Demirci

    Prof. Dr. Mehmet Demirci, born in 1979, is a professor of Medical Microbiology at Kırklareli University, researching microbiota and immunological mechanisms.

     ORCID logo     , Aleyna Karakus

    Aleyna Karakus, born in 2000, is an undergraduate Mechanical Engineering student at Istanbul Beykent University, aiming for an academic career.

         and Mihrigul Eksi Altan

    Prof. Dr. Mihrigul Eksi Altan, born in 1977, is a professor at Yildiz Technical University, Istanbul, specializing in polymer processing, polymer composites, and nanocomposites.

     ORCID logo
Published/Copyright: April 29, 2025
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Materials Testing
From the journal Materials Testing Volume 67 Issue 6

Abstract

This study examines the mechanical performance of novel PLA/PCL intervertebral cage designs for lumbar spinal fusion, using FEA and experimental compression testing. Four 3D-printed cage designs with varying graft window sizes and structural volumes were tested for load-bearing capacity. Experimental compressive strengths ranged from 43.36 MPa for Cage 4–50.43 MPa for Cage 3, all meeting the mechanical requirements of spinal applications. Cage 2, with a dual-window design, exhibited optimal load distribution and the highest compressive strength (50.00 MPa), indicating enhanced stability. Conversely, Cage 4, prioritizing graft space with the largest window, demonstrated the lowest compressive strength, revealing a trade-off between graft window size and structural support. FEA findings aligned well with experimental results, showing consistent trends in load distribution. Cage 2 exhibited the lowest von Mises stress, while Cage 4 had the highest stress concentrations, indicating vulnerability to deformation. This consistency between FEA and experimental data validates the reliability of FEA in evaluating cage designs. The findings suggest that PLA/PCL cages are viable alternatives to conventional materials, advancing the development of sustainable, patient-specific spinal fusion solutions. This study emphasizes the critical role of design in achieving a balance between structural support and potential for effective graft support in spinal implants.

Keywords: 3D printing; PLA/PCL; intervertebral cage design; finite element analysis (FEA); compressive strength
Corresponding author: Meltem Eryildiz, Department of Mechanical Engineering, Istanbul Beykent University - Ayazaga-Maslak Campus, Istanbul, Türkiye, E-mail:

Funding source: Türkiye Bilimsel ve Teknolojik Araştırma Kurumu (TUBITAK)

Award Identifier / Grant number: 123M748

About the authors

Meltem Eryildiz

Dr. Meltem Eryildiz, born in 1987, is an Associate Professor of Mechanical Engineering at Istanbul Beykent University, Turkey, specializing in additive manufacturing and polymer composites.

Ozge Altintas Kadirhan

Dr. Ozge Altintas Kadirhan, an Associate Professor of Neurology at Kırklareli University Faculty of Medicine, focuses on vascular neurology and neuroprotective treatments.

Mehmet Demirci

Prof. Dr. Mehmet Demirci, born in 1979, is a professor of Medical Microbiology at Kırklareli University, researching microbiota and immunological mechanisms.

Aleyna Karakus

Aleyna Karakus, born in 2000, is an undergraduate Mechanical Engineering student at Istanbul Beykent University, aiming for an academic career.

Mihrigul Eksi Altan

Prof. Dr. Mihrigul Eksi Altan, born in 1977, is a professor at Yildiz Technical University, Istanbul, specializing in polymer processing, polymer composites, and nanocomposites.

  1. Research ethics: Not applicable.

  2. Informed consent: Not applicable.

  3. Author contributions: The authors have accepted responsibility for the entire content of this submitted manuscript and approved submission. Meltem Eryildiz conceptualized the study, prepared the filament, conducted the cage design and analyses, interpreted the results, and led the manuscript writing. Özge Altıntaş Kadırhan and Mehmet Demirci contributed to the cage design, providing critical insights and support during the design phase. Aleyna Karakus assisted in material preparation and filament production and supported the analyses. Mihrigül Eksi Altan provided support in result interpretation, academic supervision throughout the project.

  4. Use of Large Language Models, AI and Machine Learning Tools: None declared.

  5. Conflict of interest: The authors state no conflict of interest.

  6. Research funding: This study was supported by Scientific and Technological Research Council of Turkey (TUBITAK) under the Grant Number 123M748. The authors thank to TUBITAK for their supports.

  7. Data availability: Not applicable.

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Published Online: 2025-04-29
Published in Print: 2025-06-26

© 2025 Walter de Gruyter GmbH, Berlin/Boston

Articles in the same Issue

  1. Frontmatter
  2. Effect of flush grinding on corrosion fatigue behavior of step-aged 7020 aluminum alloys
  3. Bending behavior of corrugated sandwich panels with various core shapes
  4. Comparison of crash performance of auxetic structures for CF15, PA6/GF30, and GF30PP materials
  5. Combined effect of ball milling and high-pressure torsion on mechanical properties of Al2O3/Al composite
  6. Liquid metal embrittlement susceptibility of galvanized advanced high strength steel with high manganese content
  7. Kinetic study on nickel aluminides formed on Monel 400 alloy
  8. Finite element simulation of natural gas pipelines in service welding repair
  9. Biomechanical effects of material selection and micro-groove design for dental implants
  10. Design, FEA and experimental validation of 3D-printed PLA/PCL intervertebral cages for lumbar spinal fusion
  11. Effect of tool tilt angles on the formation of YSZ/Al2O3 hybrid surface composites on friction stir processed magnesium alloy AZ31
  12. Coating of AISI 304 stainless steel surface with addition of Cr3C2 to NiCrCo medium entropy alloy powder
  13. Numerical and analytical stress analysis for a FGM beam
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https://doi.org/10.1515/mt-2024-0484
Keywords for this article
3D printing; PLA/PCL; intervertebral cage design; finite element analysis (FEA); compressive strength

Articles in the same Issue

  1. Frontmatter
  2. Effect of flush grinding on corrosion fatigue behavior of step-aged 7020 aluminum alloys
  3. Bending behavior of corrugated sandwich panels with various core shapes
  4. Comparison of crash performance of auxetic structures for CF15, PA6/GF30, and GF30PP materials
  5. Combined effect of ball milling and high-pressure torsion on mechanical properties of Al2O3/Al composite
  6. Liquid metal embrittlement susceptibility of galvanized advanced high strength steel with high manganese content
  7. Kinetic study on nickel aluminides formed on Monel 400 alloy
  8. Finite element simulation of natural gas pipelines in service welding repair
  9. Biomechanical effects of material selection and micro-groove design for dental implants
  10. Design, FEA and experimental validation of 3D-printed PLA/PCL intervertebral cages for lumbar spinal fusion
  11. Effect of tool tilt angles on the formation of YSZ/Al2O3 hybrid surface composites on friction stir processed magnesium alloy AZ31
  12. Coating of AISI 304 stainless steel surface with addition of Cr3C2 to NiCrCo medium entropy alloy powder
  13. Numerical and analytical stress analysis for a FGM beam
  14. Mechanical and wear behaviour of hybrid AA8011 metal matrix composite reinforced with aluminum silicate and titanium dioxide
  15. A new neural network–assisted hybrid chaotic hiking optimization algorithm for optimal design of engineering components
  16. Cup drawing predictions for a 6016-T4 aluminum alloy
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