Machine learning-assisted finite element modeling of additively manufactured meta-materials.
Journal:
3D printing in medicine
Published Date:
Jul 14, 2025
Abstract
Mechanical characterization of three-dimensional (3D) printed meta-biomaterials is rapidly becoming a crucial step in the development of novel medical device concepts, including those used in functionally graded implants for orthopedic applications. Finite element simulations are a valid, FDA-acknowledged alternative to experimental tests, which are time-consuming, expensive, and labor-intensive. However, when applied to 3D-printed meta-biomaterials, state-of-the-art finite element modeling approaches are becoming increasingly complex, while their accuracy remains limited. A critical condition for accurate simulation results is the identification of correct modelling parameters. This study proposes a machine learning-based strategy for identifying model parameters, including material properties and model boundary conditions, to enable accurate simulations of macro-scale mechanical behavior. To achieve this goal, a physics-informed artificial neural network model (PIANN) was developed and trained using data generated through a fully automated finite element modeling workflow. Subsequently, the PIANN model was then tested using real experimental force-displacement data as its input. The experimental data from 3D-printed structures were used to predict the associated parameters for finite element modeling. Finally, the workflow was validated by qualitatively and quantitatively comparing simulation results to the experimental data. Based on these results, we concluded that the proposed workflow could identify model parameters such that the predictions of associated finite element simulations are in agreement with experimental observations. Furthermore, resulting finite element models were found to outperform state-of-the-art models in terms of both quantitative and qualitative accuracy. Therefore, the proposed strategy has the potential to facilitate the broader application of finite element simulations in evaluating 3D-printed parts, in general, and 3D-printed meta-biomaterials, in particular.
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