Simpleware Case Study: Customized Maxillary Implant Design Optimization Using Finite Element Analysis

3D Visualization and Segmentation

A high-resolution CT scan of adequate slice thickness was used to visualize the maxilla anatomy and the neighboring area. Simpleware ScanIP software was used to import the CT data, perform segmentation and reconstruct a 3D anatomical model to help the surgeon to better visualize and understand the operation.

Custom Implant Design

As the patient had significant maxilla bone loss on their left side, the maxillary implant was designed in Geomagic Freeform software by using the healthy side as the reference. A healthy right maxilla was mirrored and superimposed with the existing maxilla. This approach helped to reconstruct the maxilla bone on the defect, ensuring the symmetry is achieved for better aesthetics. In addition, surface holes were added to the implant to help reduce weight. For dental rehabilitation, the impressions of the standard abutments were incorporated within the implant.

Finite Element Analysis

Once the final position was confirmed, the files were loaded for processing in Ansys software. The FE method was used by Jajal to solve medical structure problems involving complicated geometries, with the goal of virtually simulating real-time loading conditions and estimating implant stress and fatigue to help optimize designs. The customized maxillary implant along with the maxilla bone was analyzed to understand the implant’s design safety and performance. Virtual simulation with actual loading conditions was performed in Ansys to understand the stresses on the implant design. Von Mises stress on the implant design was 93.29 Mpa.

This design was then further optimized based on the FE results, and an acceptable desired implant design was achieved. Following this design optimization, von Mises stress was reduced to 46.645 Mpa for the second design tested, and this model was used for the surgical implantation.

3D Printing and Results

Once the surgical plan along with the implant was approved and finalized, the implant and host bones were manufactured using 3D printing. The bone models were manufactured in plastic and the implant was fabricated in medical-grade titanium. The final implant was then used as part of the final operation, whereby pre-planning the surgical approach and the use of a patient-specific model aided in achieving accurate reconstruction, reduced intra-operative time, and faster recovery for the patient.