Finite Element Analysis of Patient-Specific Cranial Implants under Different Design Parameters for Material Selection

Mejía Rodríguez, Manuel; González-Estrada, Octavio Andrés; Villegas-Bermúdez, Diego Fernando

doi:10.3390/designs8020031

Cited by 4 publications

(2 citation statements)

References 47 publications

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“…The RE process is increasingly used in many technological fields like automotive [15], aviation [18], and medicine [48,49]. It can be identified as one of the techniques for design-ing machine parts closely associated with computer-aided engineering systems.…”

Section: Discussionmentioning

confidence: 99%

Analysis of the Accuracy of CAD Modeling in Engineering and Medical Industries Based on Measurement Data Using Reverse Engineering Methods

Turek,

Bezłada,

Cierpisz

et al. 2024

Designs

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The reverse engineering (RE) process is often necessary in today’s engineering and medical industries. Expertise in measurement technology, data processing, and CAD modeling is required to ensure accurate reconstruction of an object’s geometry. However, errors are generated at every stage of geometric reconstruction, affecting the dimensional and geometric accuracy of the final 3D-CAD model. In this article, the geometry of reconstructed models was measured using contact and optical methods. The measurement data representing 2D profiles, 3D point clouds, and 2D images acquired in the reconstruction process were saved to a stereolithography (STL) model. The reconstructed models were then subjected to a CAD modeling process, and the accuracy of the parametric modeling was evaluated by comparing the 3D-CAD model to the 3D-STL model. Based on the results, the model used for clamping and positioning parts to perform the machining process and the connecting rod provided the most accurate mapping errors. These models represented deviations within ±0.02 mm and ±0.05 mm. The accuracy of CAD modeling for the turbine blade model and the pelvis part was comparable, presenting deviations within ±0.1 mm. However, the helical gear and the femur models showed the highest deviations of about ±0.2 mm. The procedures presented in the article specify the methods and resolution of the measurement systems and suggest CAD modeling strategies to minimize reconstruction errors. These results can be used as a starting point for further tests to optimize CAD modeling procedures based on the obtained measurement data.

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Section: Discussionmentioning

confidence: 99%

Analysis of the Accuracy of CAD Modeling in Engineering and Medical Industries Based on Measurement Data Using Reverse Engineering Methods

Turek,

Bezłada,

Cierpisz

et al. 2024

Designs

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show abstract

“…By refining materials and designs, the goal is to promote enhanced bone growth while mitigating the risk of rejection or associated complications from implanted devices [33]. Finite element modeling tailored to bone tissue dynamics plays a crucial role in iteratively designing and optimizing implants [34,35]. This approach enables thorough evaluations across critical parameters like load distribution and mechanical response, aiding in preemptively addressing potential complications such as fractures or implant loosening.…”

Section: Introductionmentioning

confidence: 99%

Characterization of Pig Vertebrae under Axial Compression Integrating Radiomic Techniques and Finite Element Analysis

Hernández-Salazar,

Chamorro,

González-Estrada

2024

Inventions

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The study of pig bones, due to their similarity with human tissues, has facilitated the development of technological tools that help in the diagnosis of diseases and injuries affecting the skeletal system. Radiomic techniques involving medical image segmentation, along with finite element analysis, enable the detailed study of bone damage, loss of density, and mechanical functionality, which is a significant advancement in personalized medicine. This study involves conducting experimental tests on L3–L6 pig vertebrae under axial loading conditions. The mechanical properties of these vertebrae are analyzed, and the maximum loads they can sustain within the elastic range are determined. Additionally, three-dimensional models are generated by segmenting computerized axial tomography (CAT) scans of the vertebrae. Digital shadows of the vertebrae are constructed by assigning an anisotropic material model to the segmented geometries. Then, finite element analysis is performed to evaluate the elastic characteristics, stress, and displacement. The findings from the experimental data are then compared to the numerical model, revealing a strong correlation with differences of less than 0.8% in elastic modulus and 1.53% in displacement. The proposed methodology offers valuable support in achieving more accurate medical outcomes, employing models that serve as a diagnostic reference. Moreover, accurate bone modeling using finite element analysis provides valuable information to understand how implants interact with the surrounding bone tissue. This information is useful in guiding the design and optimization of implants, enabling the creation of safer, more durable, and biocompatible medical devices that promote optimal osseointegration and healing in the patient.

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Cranial reconstruction utilizing polymeric implants in two different designs: finite element investigation

Shash

2024

BMC Musculoskelet Disord

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Introduction Impact loads applied to the human head can result in skull fractures or other injuries that require a craniectomy. The removed portion is replaced with biological or synthetic materials using cranioplasty surgery. Titanium has been the material of choice for cranial implants due to its superior properties and biocompatibility; however, its issues have prompted the search for substitute materials (e.g., polymers). The issues are related to the requirement for surface modification, casting, radiologic incompatibility and potential allergy risks. Recently, polymeric materials have been used in many fields as alternatives to titanium. Objective This research aims to conduct a finite element study to evaluate the skull reconstruction process by using PEEK and carbon fiber reinforced PEEK 30 and 60% in the production of cranial implants as alternatives to conventional titanium implants. Materials and methods A three-dimensional model of a defective skull was rehabilitated with a custom-made cranial implant. The implants were stimulated using two designs (plate and mesh), and different polymeric materials (PEEK and carbon fiber reinforced PEEK 30 and 60%) as titanium substitutes, under 2000 N impact force. Results The results illustrated that plate implants reduced the stresses on the skull and increased the stresses on brain tissues compared to mesh implants. Titanium, CFR-PEEK 30 & 60% implants (whether mesh or flat) were not prone to fracture, unlike mesh PEEK implants. In addition, CFR-PEEK 60% implants produced the lowest values of stress, strain, and total deformation on the skull and brain compared to titanium implants, unlike PEEK implants. By using the titanium plate implant, the peak tensile and compressive stresses on the skull were 24.99 and 25.88 MPa, respectively. These stresses decreased to 21.6 and 24.24 MPa when using CFR-PEEK 60%, increased to 26.07 and 28.99 MPa with CFR-PEEK 30%, and significantly increased to 41.68 and 87.61 MPa with PEEK. When the titanium mesh implant was used, the peak tensile and compressive stresses on the skull were 29.83 and 33.86 MPa. With CFR-PEEK 60%, these stresses decreased to 27.77 and 30.57 MPa, and with CFR-PEEK 30% and PEEK, the stresses increased to 34.04 and 38.43 MPa, and 44.65 and 125.67 MPa, respectively. For the brain, using the titanium plate implant resulted in peak tensile and compressive stresses of 14.9 and 16.6 Pa. These stresses decreased to 13.7 and 15.2 Pa with CFR-PEEK 60%, and increased to 16.3 and 18.1 Pa, and 73.5 and 80 Pa, with CFR-PEEK 30% and PEEK, respectively. With the titanium mesh implant, the peak tensile and compressive stresses were 12.3 and 13.5 Pa. Using CFR-PEEK 60%, these stresses decreased to 11.2 and 12.4 Pa on the brain, and increased with CFR-PEEK 30% and PEEK to 14.1 and 15.5 Pa, and 53.7 and 62 Pa, respectively. Additionally, the contact area between the PEEK implant (whether mesh or plate design) and the left parietal bone of the skull was expected to be damaged due to excessive strains. Importantly, all implants tested did not exceed permissible limits for tensile and compressive stresses and strains on the brain. Conclusion It was concluded that carbon fiber-reinforced PEEK implants, with 30% and 60% reinforcements, can be used as alternatives to titanium for cranial reconstruction. The addition of carbon fibers to the PEEK matrix in these percentages enhances the mechanical, chemical, and thermal properties of the implants. Additionally, these composites are characterized by their low weight, biocompatibility, lack of clinical issues, and ease of fabrication. They can also help preserve the skull, protect the brain, and are not susceptible to damage. Clinical significance Overcoming the drawbacks of titanium cranial implants and increasing the effectiveness of the cranioplasty process by utilizing PEEK and carbon fiber reinforced PEEK materials in the reconstruction of the damaged portion of skull.

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Finite Element Analysis of Patient-Specific Cranial Implants under Different Design Parameters for Material Selection

Cited by 4 publications

References 47 publications

Analysis of the Accuracy of CAD Modeling in Engineering and Medical Industries Based on Measurement Data Using Reverse Engineering Methods

Analysis of the Accuracy of CAD Modeling in Engineering and Medical Industries Based on Measurement Data Using Reverse Engineering Methods

Characterization of Pig Vertebrae under Axial Compression Integrating Radiomic Techniques and Finite Element Analysis

Cranial reconstruction utilizing polymeric implants in two different designs: finite element investigation

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