Electron beam melting in the fabrication of three-dimensional mesh titanium mandibular prosthesis scaffold

Abstract

The study was designed to fulfill effective work-flow to fabricate three-dimensional mesh titanium scaffold for mandibular reconstruction. The 3D titanium mesh scaffold was designed based on a volunteer with whole mandible defect. (1) acquisition of the CT data; (2) design with computer aided design (CAD) and finite element analysis (FEA). The pore size and intervals with the best mechanic strength was also calculated using FEA. (3) fabrication of the scaffold using electron beam melting (EBM); (4) implantation surgery. The case recovered well, without loosening and rejection. Additionally, 12 mandibular defect model beagles were used to verify the results. The model was established via tooth extraction and mandibular resection surgeries, and the scaffold was designed individually based on CT data obtained at 2 weeks after extraction operation. Then scaffolds were fabricated using 3D EBM, and the implantation surgery was performed at 2 months after extraction operation. All the animals healed well after implantation, and the grafted mandibular recovered well with time. The relevant parameters of the grafted mandibular were nearly to the native mandibular at postoperative 12 months. It is feasible to fabricate mesh titanium scaffold for repairing mandibular defects individually using reverse engineering, CAD and EBM techniques.

Fabrication and Analysis of a Ti6Al4V Implant for Cranial Restoration

“…Furthermore, any discrepancy would result in implant failure, a greater number of amendments and psychological stress on the patient's mind. Henceforth, to minimize disparities and conform bone contours as well as provide enhanced cosmetic output, it is imperative to make use of the concept of customized implant design [12,13]. The customized design of an implant can improve fitting accuracy significantly and reduces the operation time in contrast to standard plates.The rapidly growing health care demands owing to aging, expanding the global population, etc., emphasize the importance of innovative technologies in the medical field.…”

Combined Infection Control and Enhanced Osteogenic Differentiation Capacity on Additive Manufactured Ti‐6Al‐4V are Mediated via Titania Nanotube Delivery of Novel Biofilm Inhibitors

“…This involves incorporating existing surface modification techniques to complex AM porous architectures or developing new strategies, where achieving uniform external and internal surface modification that also meets requirements for infection control whilst simultaneously promoting osteogenic differentiation is a newly‐presented challenge. [ 18,79 ] Nevertheless, promising reported strategies under development include a study by Jia et al who investigated the combination of silver nanoparticles to micro‐arc oxidized/hydrothermal treated AM Ti‐6Al‐4V scaffold with the aid of a dopamine coating, where they described achieving the three‐in‐one goal of infection prophylaxis, infection‐fighting and bone repair. [ 77,80 ] Xu et al evaluated copper incorporated SLM Ti‐6Al‐4V surfaces populated with macrophages, osteoclasts and osteoblasts, and demonstrated suppressed inflammatory response and osteoclastogenesis, meanwhile promoting bone extracellular matrix formation by osteoblasts.…”

“…Additive manufacturing (AM) expands the possibility to fabricate complex, anatomically matched orthopedic implants. [ 17–19 ] To further increase bony integration, a number of surface modification strategies have been investigated; however, popular physical depositions have the risk of delamination (e.g., hydroxyapatite coating) and subtraction approaches might influence the mechanical and fatigue properties (e.g., sandblasting). [ 20 ] Electrochemical anodization is another appealing strategy that results in surface nano‐texturing by creating regular nanotubes on the titanium surface.…”

Biomechanical Analysis of Various Reconstructive Methods for the Mandibular Body and Ramus Defect Using a Free Vascularized Fibula Flap

“…Therefore, the type of fibular flap that is applied in surgery plays a critical role in the success of long-term stable osseointegration [11]. Many studies have reported on the use of 3D finite element analysis (FEA) in mandibular reconstruction [12][13][14][15][16]. However, most of these studies deal with a postoperative analysis.…”