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A Novel Design Method of Gradient Porous Structure for Stabilized and Lightweight Mandibular Prosthesis.

Renshun Liu1, Yuxiong Su2, Weifa Yang2

  • 1Shien-Ming Wu School of Intelligent Engineering, South China University of Technology, Guangzhou 511400, China.

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This study developed a stress-optimized gradient algorithm for mandibular prostheses, improving bone adaptation. The new gradient design enhanced load capacity and reduced stress, offering a superior solution for mandibular reconstruction.

Keywords:
functionally graded designhigh porositymandibular prosthesismechanical properties

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Area of Science:

  • Biomaterials Engineering
  • Mechanical Engineering
  • Orthopedic Surgery

Background:

  • Conventional prostheses with homogenous structures have limitations in adapting to host bone.
  • Stress-optimized, functionally gradient prostheses offer mechanical and biological advantages for better host bone integration.

Purpose of the Study:

  • To investigate the damage resistance of four regular lattice scaffolds.
  • To propose a novel gradient algorithm for stabilized and lightweight mandibular prostheses.
  • To optimize scaffold design for improved mandibular reconstruction.

Main Methods:

  • Finite element analysis (FEA) was used to evaluate four lattice scaffold configurations (regular hexahedron, octahedron, rhombic dodecahedron, body-centered cubic) at varying porosities.
  • A homogenization algorithm adjusted strut diameters to control maximum stress and increase scaffold porosity, minimizing material waste and preventing fatigue failure.
  • Compression tests were performed to validate the algorithm's effectiveness and simulation results.

Main Results:

  • Scaffold load transmission capacity correlated strongly with unit cell configuration and porosity; regular hexahedron scaffolds supported higher loads at equivalent porosity.
  • The optimized gradient scaffold exhibited higher porosity and lower maximum stress than the target value, confirmed by compression tests.
  • A mandibular prosthesis using the gradient algorithm demonstrated a 24.48% reduction in maximum stress and a 6.82% increase in porosity compared to homogeneous designs.

Conclusions:

  • Regular hexahedron unit cells are optimal for load-bearing scaffolds in mandibular prostheses.
  • The proposed gradient algorithm effectively optimizes scaffold design for enhanced mechanical properties and reduced stress.
  • Functionally gradient mandibular prostheses represent a significant improvement for patient outcomes in reconstruction.