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Patients with oral cancer often have to undergo the surgery for mandibular excision. Once the bone in the cancerous area is removed, not only the facial area but also chewing function of the patient is needed to be repaired by clinicians. In recent years, the rapid growth of three-dimensional (3D) metal printing technology has meant that higher-quality facial reconstructions are now possible, which could even restore chewing function. This study developed 3D-printed titanium (Ti)-alloy reconstruction implant for a prosthesis designed for mandibular segmental osteotomy defects, and 3D finite element (FE) analysis was conducted to evaluate its biomechanical performance. The analyzed parameters in the FE models were as follows: (1) two prosthesis designs, namely a prosthesis retaining the residual mandibular bone (for patients with mild oral cancer) and a prosthesis with complete mandibular resection (for patients with severe oral cancer); (2) two lengths of prosthesis, namely 20 and 25 mm; and (3) three thicknesses of prosthesis, namely 0.8, 1, and 1.5 mm. A 45° lateral bite force (100 N) was applied to the top of the prosthesis as the loading condition. The results revealed that for the two prosthesis designs, the prosthesis retaining the residual mandibular bone showed higher stress on the prosthesis and cortical bone compared with the prosthesis with complete mandibular resection. Regarding the two prosthesis lengths, no fixed trend of prosthesis stress was found, but stress in the cortical bone was relatively high for a prosthesis length of 20 mm compared with that of 25 mm. For the three prosthesis thicknesses, as the thickness of the prosthesis decreased, the stress in the prosthesis decreased but the stress in the cortical bone increased. These findings require confirmation in future clinical investigations.

metals

Biomechanical Assessment of Design Parameters on a Self-Developed 3D-Printed Titanium-Alloy Reconstruction/Prosthetic Implant for Mandibular Segmental Osteotomy Defect