Case Study: KU Leuven achieves accurate, robust finite‑element femur models for interprosthetic gap analysis with Materialise

Furthering Orthopaedic Research through Enhanced Remeshing

Researchers at KU Leuven’s Biomechanics Section sought to understand whether the “interprosthetic gap” between hip and knee implants affects femoral strength and needed a robust workflow to create accurate finite element (FE) models. To do this they used Materialise’s tools — notably the Materialise Mimics Innovation Suite and Materialise 3-matic — to convert CT data into anatomically accurate 3D bone and implant models and to simulate multiple implant-position combinations.

Using Materialise Mimics for Hounsfield‑unit segmentation and 3-matic for stem adaptation, non‑manifold assembly creation and advanced remeshing, the team generated uniform surface and volume meshes, exported high‑quality tet10 meshes to Abaqus, and ran FE analyses for ~30 prosthesis combinations. Materialise’s workflow greatly reduced manual corrections, produced consistent mesh quality, and showed that interprosthetic gaps had higher local strains but were not overall stress risers versus bone without implants — enabling reliable, efficient simulations and measurable time savings in model preparation.

KU Leuven

Jos Vander Sloten

Biomechanics Section, Department of Mechanical Engineering, Faculty of Engineering