Dual-zone material assignment method for correcting partial volume effects in image-based bone models

In image-based finite element analysis of bone, partial volume effects (PVEs) arise from image blur at tissue boundaries and as a byproduct of geometric reconstruction and meshing during model creation. In this study, we developed and validated a material assignment approach to mitigate partial volume effects. Our validation data consisted of physical torsion testing of intact tibiae from N = 20 Swiss alpine sheep. We created finite element models from micro-CT scans of these tibiae using three popular element types (10-node tetrahedral, 8-node hexahedral, and 20-node hexahedral). Without partial volume management, the models over-predicted the torsional rigidity compared to physical biomechanical tests. To address this problem, we implemented a dual-zone material model to treat elements that overlap low-density surface voxels as soft tissue rather than bone. After in situ inverse optimization, the dual-zone material model produced strong correlations and high absolute agreement between the virtual and physical tests. This suggests that with appropriate partial volume management, virtual mechanical testing can be a reliable surrogate for physical biomechanical testing. For maximum flexibility in partial volume management regardless of element type, we recommend the use of the following dual-zone material model for ovine tibiae: soft-tissue cutoff density of 665 mgHA/cm³ with a soft tissue modulus of 50 MPa (below cutoff) and a density-modulus conversion slope of 10,225 MPa-cm³/mgHA for bone (above cutoff).