The topology optimization design and processing of 3D-printed bio-fixed bone plate applied to the mandible

To achieve a personalized bio-fixed mandibular bone plate with high matching, mechanical properties, and biocompatibility, this study employed a combination of reverse and forward design methodologies to complete modeling of the mandibular bone plate. Stress analysis was conducted on eight working conditions. Subsequently, under the most extreme condition, topology optimization was applied to refine the shape of the bone plate, followed by filling it with hexahedral lattice structures. Finally, SLM equipment was employed to fabricate the bio-fixed mandibular bone plate, and its performance was evaluated. The results indicate that after topology optimization and porous structure filling, the weight of the plate decreased from 5.47 g to 2.82 g (a reduction of 49%), while the maximum stress increased from 214.1 MPa to 350.9 MPa (an increase of 64%), and the maximum displacement increased from 0.6669 mm to 0.9722 mm (an increase of 45.78%). This enhancement can effectively mitigate stress-shielding effects. The 3D-printed personalized bio-fixed bone plate features a smooth surface, clear pore structure, and excellent bonding. The fit between the bone plate and the mandible model is tight and easy to install, meeting the required standards. This study provides a robust foundation for the application of SLM in manufacturing personalized bio-fixed bone plates.