Effect of different titanium mesh thicknesses on mechanical strength and bone stress: a finite element study

This study aimed to investigate the influence of different titanium mesh thicknesses (0.1 mm, 0.2 mm, and 0.3 mm) on mechanical durability and stress distribution in guided bone regeneration using finite element analysis (FEA).

Three-dimensional mandibular bone models were reconstructed from cone-beam computed tomography (CBCT) data of a patient with a posterior alveolar defect. Custom titanium meshes with varying thicknesses were designed and virtually applied to the defect area. All models were subjected to a vertical force of 30 N to simulate masticatory loading. FEA simulations were performed using ALTAIR Hypermesh and OptiStruct software to evaluate von Mises stress distribution across the mesh, graft, and bone.

The 0.1 mm mesh exhibited the highest stress concentrations (981.569 MPa), indicating a high risk of plastic deformation and potential graft damage (35.287 MPa). The 0.2 mm mesh provided moderate protection with improved stress distribution (mesh: 452.218 MPa, graft: 11.589 MPa). The 0.3 mm mesh showed the best mechanical performance, with the lowest stress values on both the mesh (226.205 MPa) and the graft (7.785 MPa). Bone stress remained below critical thresholds in all models.

Mesh thickness significantly affects the mechanical behavior and stress shielding capacity of titanium meshes in GBR applications. A thickness of 0.3 mm offers the most reliable mechanical performance. However, 0.2 mm meshes may serve as a viable alternative in cases requiring greater flexibility or lower cost, with caution toward borderline graft stress.