Ahmad, Fatima Ajaz creator Supervisor : Dr. Nabeel Anwar text monographic 93p. Soft Copy 30cm Fatima Ajaz Ahmad Total Knee Replacement (TKR) surgeries are becoming increasingly common globally as an effective measure to counter knee arthritis. Total knee replacement implants are very advantageous in a sense that they offer 99% success rate to patients. This thesis presents the design, simulation and additive manufacturing of a patient specific, Functionally Graded Lattice Structure (FGLS) knee implant in Ti 6Al-4V alloy with specific reference to the healthcare situation in Pakistan. This was to explore the local manufacturing facilities of Pakistan as all knee implants are imported from abroad. The strategy involved a high degree of workflow consisting of Computer-Aided Design (CAD), finite element analysis (FEA), and topology optimization using nTopology to create Gyroid-based lattice work. The structures were to resemble the trabecular bone structure to ensure that stiffness discrepancies were minimized. This helped counter only one drawback of solid knee implants, stress shielding. The simulations of the physiological loading conditions (static and cyclic) demonstrated a Von Mises peak of 620.45 Mpa and safety factor of 12.66 on the average and unlimited predicted life of fatigue of over 10^7 cycles. The use of FGLS was effective in making the weight of 490 g to 292, leading to a 40 percent weight reduction, with no structural integrity lost. Selective Laser Melding (SLM) was used to fabricate the implant and the heat treatment allowed stress relieving of the additively manufactured implant. Compressive testing was also mechanically vindicated to be on an of average 95.02 kN with little variation and Micro-CT scanning confirmed high dimensional fidelity and showed internal lattice geometries without defects. According to this research, SLM produced FGLS implants usage has proven to be an option to traditional prosthetics, which is mechanically stable, biologically desirable, and cost-effective, and has a bright future of being a locally manufactured orthopedics product. MS Biomedical Engineering (BME) 610 http://10.250.8.41:8080/xmlui/handle/123456789/57064 http://10.250.8.41:8080/xmlui/handle/123456789/57064