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Anatomical Thin Titanium Mesh Plate Structural Optimization for Zygomatic-Maxillary Complex Fracture under Fatigue

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|June 12, 2018
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This study optimized anatomical thin titanium mesh (ATTM) plates using additive manufacturing for superior ZMC fracture stabilization. The enhanced design significantly reduced bone micromotion and strain compared to traditional miniplates.

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Area of Science:

  • Biomaterials Engineering
  • Orthopedic Surgery
  • Mechanical Engineering

Background:

  • Anatomical thin titanium mesh (ATTM) plates are used for facial fracture fixation.
  • Optimizing ATTM plate design is crucial for improving stabilization and reducing complications.

Purpose of the Study:

  • To structurally optimize ATTM plates using finite element analysis and the Taguchi method.
  • To fabricate and evaluate an optimized ATTM plate using additive manufacturing (AM) for Zygomaticomaxillary Complex (ZMC) fractures.

Main Methods:

  • Finite element (FE) analysis simulated the structural bending resistance of regular ATTM plates.
  • The Taguchi method identified key design factors (hole distance, hole diameter, plate thickness, plate height) influencing deflection.
  • An optimized, patient-matched ATTM plate was fabricated via AM and tested under fatigue conditions for ZMC comminuted fractures.

Main Results:

  • Taguchi analysis determined optimal design parameters: 0.9 mm hole distance, 1 mm hole diameter, 0.8 mm plate thickness, and 10 mm plate height.
  • Plate thickness was the most significant factor, contributing 78% to bending resistance.
  • The optimized AM ATTM plate demonstrated significantly lower maxillary bone micromotion and strain compared to traditional miniplates.

Conclusions:

  • Combining FE and Taguchi analyses yields an optimal ATTM plate design with sufficient strength.
  • The AM-fabricated, patient-matched ATTM plate offers superior stabilization for ZMC comminuted fractures.