Additively manufactured titanium stents: Stress analysis and surface finishing

Purpose The purpose of this study is to enhance the performance and reliability of additively manufactured (AM) cardiovascular stents by integrating computational stress analysis with an advanced finishing process to improve their structural integrity and surface quality. Design/methodology/approach A comprehensive finite element analysis (FEA) was conducted in ABAQUS to simulate the mechanical behavior of different designed AM titanium alloy stents under physiological loading conditions, such as crimping and deployment. This study focused on the following key performance indicators, including the dog-boning effect, radial recoil and stress distribution. To enhance surface quality, Magnetorheological Shear Thickening Polishing (MRSTP) was applied to the AM titanium alloy stents, resulting in a significant reduction in surface roughness and the elimination of micro-defects. Analyses of surface morphology and 3D profilometry verified nanometric surface finishes, indicating a surface conducive to improved biocompatibility. Findings The FEA simulations offered valuable insights into mechanical performance, guiding design optimization. The MRSTP process significantly reduced surface roughness, achieving nanometric finish and minimizing manufacturing defects. The integration of finishing and FEA resulted in superior surface integrity and structural durability, suggesting a strong potential for enhanced biocompatibility and improved long-term clinical performance. Originality/value This study introduces a novel framework that merges computational stress analysis with precision MRSTP to advance the development of AM titanium stents. Unlike earlier studies that addressed computational modelling and surface finishing independently, this work introduces a coupled strategy that integrates design optimization with advanced finishing, simultaneously enhancing structural mechanics and achieving nanometric surface smoothness. The combined improvement in both mechanical reliability and surface morphology highlights the work’s novel contribution and its significant promise for clinical application in advanced vascular stents.