Prototype design of porous Ti6Al4V intraosseous implant for use in mandibular reconstruction

The design of patient-specific implants often requires computer simulations for the characterization of mechanical properties before manufacturing. We previously developed numerical models to predict the mechanical properties of porous Ti6Al4V constructs built using laser powder bed fusion (LPBF). Here, we developed a patient-specific porous intraosseous mandibular implant based on the models and techniques described in our previous research. The implant model used a simple cubic porous design with an average unit cell size of 1 mm and strut thicknesses between 350 and 450 μm. Finite element analysis was used to simulate right molar clenching on the mandible with and without the implant, under static and dynamic loading. The simulation showed that the implant would remain intact during right molar clenching and should not cause stress shielding. The fatigue numerical models predicted that the implant would remain functional under cyclic masticatory forces (50–100 N) for a period ranging between 4 and 119 years. Given that, within one year, bone ingrowth and osseointegration are complete, the implant is predicted to remain intact long-term under physiological loading conditions. These findings demonstrate the potential of computational modelling in developing patient-specific designs for porous implants built through LPBF.