Integrative Innovation in Genioplasty: Advanced 3D Plate Design: Promoting Stability, Aesthetics, and Harmony Excellence.

Background: Genioplasty is a well-established surgical technique for reshaping the chin and enhancing facial harmony. However, conventional fixation methods may present biomechanical and aesthetic limitations.

Objective: This study introduces and evaluates a novel Anatomical Chin Plate (ACP), designed to enhance mechanical performance and facial aesthetics compared to the conventional chin plate (CP).

Methods: A three-dimensional finite element analysis (FEA) was conducted to compare stress distribution in ACP and CP models under a standardized oblique load of 60 N, simulating muscle forces from the mentalis and digastric muscles. Plates were modeled using Blender and analyzed using ANSYS software 2025 r2. Mechanical behavior was assessed based on von Mises stress, concentration sites, and potential for plastic deformation or fatigue failure.

Results: The ACP demonstrated a significantly lower maximum von Mises stress (77.19 MPa) compared to the CP (398.48 MPa). Stress distribution in the ACP was homogeneous, particularly around the lateral fixation holes, while the CP exhibited concentrated stress between central screw holes. These findings indicate that the anatomical geometry of the ACP enhances load dispersion, reduces critical stress concentrations, and minimizes fatigue risk.

Conclusions: The ACP design offers superior biomechanical behavior and improved aesthetic potential for genioplasty procedures. Its optimized shape allows for better integration with facial anatomy while providing stable fixation. Further studies are recommended to validate in vitro performance and explore clinical applicability in advanced genioplasty and complex osteotomies.