To address the poor implant integration caused by the mismatch between cross-scale transmission of mechanical signals and inadequate simulation of the cellular microenvironment during joint motion, this paper proposes a gradient multi-material 3D printing method guided by multiscale biomechanical modeling. In the specific implementation, a multiscale finite element model driven by gait data is used to analyze mechanical transmission laws from the tissue to the cellular level during joint movement, and the mechanical window that maintains cellular homeostasis is extracted in reverse by combining atomic force microscopy and molecular pathway analysis. Based on this, a biomimetic design is constructed that couples the elastic modulus index gradient with the distribution of biological factors. Through the fusion process of DLP and inkjet printing, the exposure time and ceramic concentration are controlled to achieve gradient molding of PEGDA/β-TCP composite materials. This paper uses the level set method to optimize the interface topology, generate an interpenetrating network that resists stress concentration, and verify geometric accuracy through confocal imaging, thereby enabling the precise manufacturing of structurally and functionally integrated bionic joint implants. Experiments demonstrate that the proposed method achieves a mean gradient smoothness of at least 4.59 × 103 μm and a mean stress concentration factor of no more than 1.23 under both loading conditions, effectively mitigating mechanical mismatch at interfaces.
Furthermore, the proposed method demonstrates the highest compliance matching coverage (average 88.5%–93.7%) across various physiologically relevant interface states, with respect to the accuracy of mechanical parameter reconstruction of the cell microenvironment. The error range is minimal (average range is 3.8 kPa–5.1 kPa), effectively simulating the cellular microenvironment. This work provides a new, programmable, and verifiable path to address the challenge of functional integration between implants and host tissues.
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