Establishment of an architecture-specific experimental validation approach for finite element modeling of bone by rapid prototyping and high resolution computed tomography.

A new experimental validation method for assessing the accuracy of large-scale finite element (FE) models of bone micro-structure at the apparent and tissue level was developed. Augmented scaled bone replicas were built using rapid prototype machines based on micro-computed tomography (micro-CT) data. The geometric accuracy of the model was evaluated by comparing experimental tests with the replicas to the FE solution based on the same micro-CT data. A new version of the large-scale FE solver was developed to incorporate orthotropic material properties, hence the experimentally determined properties of the rapid prototype material were input into the FE models. The modified FE solver predicted the experimental apparent level stiffness within less than 1%, and the difference between experimental strain gauge measurements and FE-calculated surface stresses was 7% and 49% on a flat and curved surface region, respectively. While absolute error estimates of surface stresses were limited due to strain gauge errors, the relatively larger difference on the curved surface is indicative of the limitations of a hexahedron FE model for representing such geometries. Although the validation approach is applied here for hexahedron based meshes, the method is flexible for varying bone architectures and will be important for validation of future large-scale FE modeling developments that utilize techniques such as mesh smoothing and tetrahedron elements.