Anatomical Thin Titanium Mesh Plate Structural Optimization for Zygomatic-Maxillary Complex Fracture under Fatigue Testing

Abstract

This study performs a structural optimization of anatomical thin titanium mesh (ATTM) plate and optimal designed ATTM plate fabricated using additive manufacturing (AM) to verify its stabilization under fatigue testing. Finite element (FE) analysis was used to simulate the structural bending resistance of a regular ATTM plate. The Taguchi method was employed to identify the significance of each design factor in controlling the deflection and determine an optimal combination of designed factors. The optimal designed ATTM plate with patient-matched facial contour was fabricated using AM and applied to a ZMC comminuted fracture to evaluate the resting maxillary micromotion/strain under fatigue testing. The Taguchi analysis found that the ATTM plate required a designed internal hole distance to be 0.9 mm, internal hole diameter to be 1 mm, plate thickness to be 0.8 mm, and plate height to be 10 mm. The designed plate thickness factor primarily dominated the bending resistance up to 78% importance. The averaged micromotion (displacement) and strain of the maxillary bone showed that ZMC fracture fixation using the miniplate was significantly higher than those using the AM optimal designed ATTM plate. This study concluded that the optimal designed ATTM plate with enough strength to resist the bending effect can be obtained by combining FE and Taguchi analyses. The optimal designed ATTM plate with patient-matched facial contour fabricated using AM provides superior stabilization for ZMC comminuted fractured bone segments.

Mechanical, Histological, and Scanning Electron Microscopy Study of the Effect of Mixed-Acid and Heat Treatment on Additive-Manufactured Titanium Plates on Bonding to the Bone Surface

“…Therefore, artificial bone with shape-recovery capacity and high compatibility with the living body has long been needed to solve these problems, and customized artificial bone, in which hard tissues are artificially created based on computed tomography (CT) scans of a patient, has been in development [ 4 , 5 , 6 ]. In particular, titanium (Ti), which has high biocompatibility, has been used in many implantable medical devices in clinical settings, including artificial joints and dental implants, and its high efficacy and safety have been demonstrated [ 7 , 8 , 9 , 10 , 11 , 12 ]. Of the customizable technologies, additive manufacturing (AM) using the selective laser technique, which creates artificial bone with Ti particles based on CT scans of a patient, has attracted attention [ 13 , 14 , 15 ].…”

Reconstruction of Complex Acromion Nonunions and Fractures With a Locking Mesh Plate

“…The mesh plate originally was a titanium design that has traditionally been used by ENT and plastic surgeons for reconstruction of complex cranial bone and orbital wall fractures with good outcomes being reported in terms of reduction efficiency and fracture stabilization. [20][21][22][23][24][25] The current form used in this series is a stainless-steel design and the implant was intended for complex mid-foot surgery. Recent orthopedic literature has applied the use of the mesh plate for foot and patella reconstructive operations with successful union rates and healing.…”

New methods for craniofacial bone reconstruction: review

“…This outcome in numerous clinical difficulties, involving insert burst, erosion, debilitating of the screws, and bone resorption (14,15). Forming and twisting titanium network plates can be testing and can prompt blunders (16).…”