Digital Design, Analysis and 3D Printing of Prosthesis Scaffolds for Mandibular Reconstruction

Segmental mandibular reconstruction has been a challenge for medical practitioners, despite significant advances in medical technology. There is a recent trend in relation to customized implants, made up of porous structures. These lightweight prosthesis scaffolds present a new direction in the evolution of mandibular restoration. Indeed, the design and properties of porous implants for mandibular reconstruction should be able to recover the anatomy and contour of the missing region as well as restore the functions, including mastication, swallowing, etc. In this work, two different designs for customized prosthesis scaffold have been assessed for mandibular continuity. These designs have been evaluated for functional and aesthetic aspects along with effective osseointegration. The two designs classified as top and bottom porous plate and inner porous plate were designed and realized through the integration of imaging technology (computer tomography), processing software and additive manufacturing (Electron Beam Melting). In addition, the proposed designs for prosthesis scaffolds were analyzed for their biomechanical properties, structural integrity, fitting accuracy and heaviness. The simulation of biomechanical activity revealed that the scaffold with top and bottom porous plate design inherited lower Von Mises stress (214.77 MPa) as compared to scaffold design with inner porous plate design (360.22 MPa). Moreover, the top and bottom porous plate design resulted in a better fit with an average deviation of 0.8274 mm and its structure was more efficiently interconnected through the network of channels without any cracks or powder material. Verily, this study has demonstrated the feasibility and effectiveness of the customized porous titanium implants in mandibular reconstruction. Notice that the design and formation of the porous implant play a crucial role in restoring the desired mandibular performance