A semi-automated design workflow for patient-specific implants in orthognathic surgery using generative design

Area of Science:

• Biomedical Engineering
• Surgical Technology
• Computational Design

Background:

• Patient-specific implants (PSIs) enhance orthognathic surgery outcomes but face design complexities and high costs.
• Current PSI design processes are time-consuming, limiting their widespread clinical adoption.

Purpose of the Study:

• To develop and evaluate a novel workflow for designing PSIs using generative design (GD) techniques.
• To streamline and accelerate the PSI design process for orthognathic surgery.

Main Methods:

• Implemented a generative design workflow using Autodesk Fusion software.
• Tested the workflow by designing PSIs for Le Fort I osteotomy and genioplasty cases.
• Assessed design time and biomechanical properties (maximum von Mises stress) of the GD PSIs.

Main Results:

• Reduced hands-on design time to 94 minutes for a Le Fort I plate and 45 minutes for a genioplasty plate.
• Achieved maximum von Mises stresses of 227.63 MPa (Le Fort I) and 237.31 MPa (genioplasty), indicating structural integrity.
• The GD workflow demonstrated simplification and acceleration of PSI design.

Conclusions:

• The generative design-based workflow effectively simplifies and accelerates PSI design for orthognathic surgery.
• Biomechanical analysis supports the clinical feasibility of generative designed patient-specific implants.