Custom-Made Titanium Mesh Tray for Mandibular Reconstruction Using an Electron Beam Melting System

Area of Science:

• Oral and Maxillofacial Surgery
• Materials Science
• Biomedical Engineering

Background:

• Mandibular reconstruction often utilizes titanium mesh trays and autologous bone.
• Material failures, like broken trays, can compromise long-term functional outcomes.

Purpose of the Study:

• To determine optimal conditions for fabricating strong, custom-shaped titanium mesh trays for mandibular reconstruction.
• To leverage computer-aided design, manufacturing, and electron beam additive manufacturing for improved tray design.

Main Methods:

• Ti-6Al-4V titanium alloy powder was used with an electron beam melting (EBM) system.
• Mechanical strength was tested on plate and tray-shaped specimens under various conditions (stretch vs. stacking direction, surface treatment).
• Topology optimization and honeycomb structures were evaluated for tray-shaped specimens.

Main Results:

• Specimens exhibited excellent mechanical strength when stretched vertically in the stacking direction with surface treatment.
• Optimized tray-shaped specimens (1.2 mm thickness) achieved a 20% weight reduction.
• Honeycomb structures enabled trays to withstand an assumed 2000 N bite force.

Conclusions:

• The EBM system is a viable technique for producing custom-designed titanium mesh trays for mandibular reconstruction.
• Optimized manufacturing conditions and structural designs (e.g., honeycomb) yield trays with sufficient strength and reduced weight.
• This approach offers a promising solution for enhancing the long-term functionality of mandibular reconstructions.