Novel and accurate 3D-Printed surgical guide for mandibular reconstruction with integrated dental implants

Patients with mandibular defects due to trauma or infiltrated disease are in a need of functional mandibular implants that will completely restore the function of their lower jaw. One of the most important roles of well-functioning jaw is mastication, a complex mechanism. A conventional approach used in oral and maxillofacial surgery accomplish this aim via two major surgeries- mandibular reconstruction and surgical placement of dental implants. Little work has been done on combining the two surgeries into with using Additive Manufacturing (AM) and digital planning.

This case study offers a mandibular implant design solution with pre-positioned dental implants that can reduce the requirement to only one surgery. Mandibular implant was designed using 3-Matic software (Materialise, Belgium). Positions for dental implants were restoratively-driven and planned on the designed mandibular implant in Blue Sky Plan 4 software (Blue Sky Bio, USA) and placed prior to mandibular reconstruction using a 3D-printed surgical guide. Finite Element Analysis (FEA) was used to evaluate the mechanical behaviour of the 3D-printed surgical guide during dental implant placement.

The surgical guide was fabricated using SLA and stress distribution was evaluated in ANSYS Workbench FEM software (Ansys Inc Swanson, Houston, USA). Results showed that the designed surgical guide can withstand the forces occurring during the surgery.

The proposed method substantially reduces the surgical procedure and recovery time, increases the accuracy, and allows for a predictable restorative solution that can be visualised from the beginning.