Mechanical and geometrical study of 3D printed Voronoi scaffold design for large bone defects

•The Voronoi structure was used to design a patient specific bone scaffold matched to a critical-sized femur defect.•Crucial surgical requirements and manufacturing constraints necessary to facilitate clinical translation of a scaffold design workflow have been accommodated.•Geometrically comparing digitized 3D prints against their designed model is an effective method to assess the fabrication accuracy of scaffolds.•Finite element method models were able to accurately predict the failure locations of the scaffold identified via the compression test.