Evaluation of contributions of orthodontic mini-screw design factors based on FE analysis and the Taguchi method

This study determines the relative effects of changes in bone/mini-screw osseointegration and mini-screw design factors (length, diameter, thread shape, thread depth, material, head diameter and head exposure length) on the biomechanical response of a single mini-screw insertion. Eighteen CAD and finite element (FE) models corresponding to a Taguchi L(18) array were constructed to perform numerical simulations to simulate mechanical responses of a mini-screw placed in a cylindrical bone. The Taguchi method was employed to determine the significance of each design factor in controlling strain. Simulation results indicated that mini-screw material, screw exposure length and screw diameter were the major factors affecting bone strain, with percentage contributions of 63%, 24% and 7%, respectively. Bone strain decreased obviously when screw material had the high elastic modulus of stainless/titanium alloys, a small exposure length and a large diameter. Other factors had no significant on bone strain. The FE analysis combined with the Taguchi method efficiently identified the relative contributions of several mini-screw design factors, indicating that using a strong stainless/titanium alloys as screw material is advantageous, and increase in mechanical stability can be achieved by reducing the screw exposure length. Simulation results also revealed that mini-screw and bone surface contact can provide sufficient mechanical retention to perform immediately load in clinical treatment.