Topology optimization and manufacturing of maxillofacial patient specific implant using FEA and AM

Patient-specific implants have gained significant attention due to their adaptability and precision in addressing individual anatomical variations. However, optimizing the strength-to-weight ratio remains a critical design challenge. This study focuses on the analysis and topological optimization of patient-specific implants to enhance their mechanical performance while minimizing weight. Finite Element Analysis (FEA) is employed to evaluate the maximum mastication force that a maxillofacial implant can withstand, ensuring that stress distribution and deformation remain within acceptable limits. Given the crucial role of mastication forces in implant stability and longevity, design iterations are conducted to achieve an improved strength-to-weight ratio. The optimized design undergoes validation through FEA under identical boundary and loading conditions. Results indicate a 4.43 % reduction in implant weight with a marginal 4 μm increase in deformation compared to the non-optimized design. To manufacture the optimized implant with high precision and structural integrity, Direct Metal Laser Sintering (DMLS), an advanced Additive Manufacturing (AM) technique, is utilized. This approach enables the fabrication of complex geometries while maintaining superior mechanical properties, ensuring the feasibility of the optimized implant for clinical applications.