Design of a patient-specific mandible reconstruction implant with dental prosthesis for metal 3D printing using integrated weighted topology optimization and finite element analysis.

The aim of this study was used a weighted topology optimization method to design a patient-specific mandibular implant for reconstruction and restoration of appearance in patients with severe mandibular defects. A finite element (FE) model was constructed and the defect region was defined from the unilateral first premolar to the second molar. The reconstruction implant included main body, fixation wing and dental prosthesis. Standard topology optimization was performed using stress constraint to identify optimal fixation wing structure (denoted as WOS) with solid core main body. Two independent optimal main body with internal beam supporting structures defined as WOSA and WOSO optimized from the WOS model under axial and oblique conditions were then obtained, respectively. Final optimal model (WBOS) was generated using a weighted topology optimization that considered 60% and 40% contributions of WOSA and WOSO models, respectively. The WBOS model was fabricated using metal 3D printing and fixed on the resting acrylonitrile butadiene styrene (ABS) bone to perform fracture testing. Stress concentration were found in the upper area connected to the main body of the mesial wing and corresponding maximum values under axial/oblique loads were reduced from 778/925 MPa of the WOS model to 764/720 MPa of the WBOS model. The reduction in percentage variations of weight between original (91.1 g) and final optimal (24.5 g) models was 73.14% for fabricated 3D printing models. The WBOS model also exhibited a higher resistant force (2163 N) when compared with the original model (1678 N). This study developed a design strategy with weighted topology optimization and fabrication for producing patient-specific implants using metal 3D printing. The obtained reconstruction implant can provide good biomechanical performance and recovery of appearance for oral rehabilitation.