3D-printed PEEK implant for mandibular defects repair - a new method

Area of Science:

• Oral and Maxillofacial Surgery
• Biomaterials Engineering
• Biomechanical Engineering

Background:

• Reconstructing large mandibular defects presents significant challenges in oral and maxillofacial surgery, often resulting in suboptimal outcomes and complications.
• Existing methods for mandibular reconstruction struggle with functional repair and long-term stability.

Purpose of the Study:

• To develop and evaluate a novel functional repair method for large mandibular defects.
• To combine 3D-printed polyetheretherketone (PEEK) implants with free vascularized fibula grafts for enhanced mandibular reconstruction.
• To assess the biomechanical performance and stability of this combined approach under masticatory loads.

Main Methods:

• Established design criteria and workflows for mandibular reconstruction focusing on safety, functionality, and shape consistency.
• Utilized finite element analysis to investigate biomechanical behavior and mechanobiological properties under simulated masticatory motion.
• Applied the novel repair method in clinical settings.

Main Results:

• Finite element analysis confirmed the safety of the repair method, with maximum stress below material yield strength and a safety factor exceeding 2.3.
• The reconstructed model exhibited less deformation than a normal mandible during clenching, ensuring primary stability.
• Over 80% of bone graft elements received effective mechanical stimulation, mitigating bone resorption risks.

Conclusions:

• The combined 3D-printed PEEK implant and vascularized fibula graft technique offers a safe and stable solution for functional and aesthetic mandibular reconstruction.
• This novel method demonstrates superior clinical performance compared to conventional fibular bone grafting techniques.
• The study provides a promising advancement in addressing complex mandibular defects.