Abstract: A method of manufacturing a femoral stem for a hip implant includes forming a femoral neck extending from a proximal end of the femoral stem towards a distal end of the femoral stem, forming an upper section connected to and extending from the femoral neck towards the distal end of the femoral stem, and forming a lower section connected to and extending from the upper section to the distal end of the femoral stem. Further, a method for designing a femoral stem for a hip implant includes generating a customized femoral stem model to match an information of a patient, generating at least one proximal-distal solid rib in the upper section, calculating density and stress distributions for an open lattice and for a closed lattice, and selecting a unit cell type and a pore size for the open lattice and the closed lattice to match a density and/or a stiffness of the patient's femur.

Abstract: Disclosed are femoral stem for hip implants, and methods of design and manufacture thereof. A femoral stem for a hip implant, comprising a femoral neck extending from a proximal end of the femoral stem towards a distal end of the femoral stem; an upper section connected to and extending from the femoral neck towards the distal end of the femoral stem, wherein the upper section comprises at least one proximal-distal solid rib flanked by an open lattice; and a lower section connected to and extending from the upper section to the distal end of the femoral stem, wherein the lower section comprises a closed lattice enclosed in a solid skin. Such femoral stems for hip implants are customized and manufactured using 3D printing technologies and provide a lightweight alternative to conventional him implants.