Abstract
Additive manufacturing has proven to be a very beneficial production technology in the medical and healthcare industries. While existing for over four decades, recent work has seen great improvements in the quality of products; particularly in medical devices such as implants. Improved customization reduced operating time and increased cost-effectiveness associated with Metal AM for these products offers a new value proposition. This paper investigates and evaluates modelling methods for the zygoma bone (human jawbone) and explores the most suitable material and optimum design for this critical biomedical implant. This paper proposes an innovative and efficient pre-process methodology that includes modelling, design validation, topological optimization, and numerical analysis. The method includes the generation of the model using reverse engineering of CT scan data and a topology optimization technique which makes the implant lightweight without causing excessive stress concentration. Static structural Finite Element Analysis was conducted to test three different biocompatible materials (Ti6Al4V, stainless steel 316L and CoCr alloys) which are commonly available for metal additive manufacturing. The stresses and conditions in the analysis were that of the human mastication process and all the implant design were tested with the three material types. The Taguchi method was used to determine the optimum design which was found to result in the highest mass reduction of 25% with Ti6Al4V as the implant material.
Highlights
It has been reported that the zygomatic bone is the third most commonly fractured facial area which is most commonly caused due to traffic accidents [1]
This paper focuses on reconstructing a patient-specific zygoma implant and predicting the suitability of the implant models made of different biocompatible metallic materials
Various responses were calculated using the Finite element method in ANSYS Workbench Mechanical such as Maximum Equivalent Von-Mises Stress, Maximum Principal Stress, Maximum Deformation, Strain Energy and the von Mises and Maximum Principal stresses at the pillar regions such as Zygomatic body, Zygomatic alveolar crest, Zygomatic body, Temporal process of the zygomatic bone, Frontal process of the zygomatic bone, Zygomatic process of the frontal bone
Summary
It has been reported that the zygomatic bone is the third most commonly fractured facial area which is most commonly caused due to traffic accidents [1]. This type of fracture is referred to as maxofacial trauma. This paper focuses on reconstructing a patient-specific zygoma implant and predicting the suitability of the implant models made of different biocompatible metallic materials. The paper addressed identifying a more optimum design which can be 3D printed using the identified biocompatible materials. Implants which match the morphology of the original bones can be manufactured using 3D printing. Validation of the design with regards to compatibility and strength must be done before manufacturing and can be completed using the Finite Element Method (FEM)
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