Published in the Rapid Prototyping Journal, this case study presents a comprehensive design and fabrication strategy for a patient-specific titanium mandibular implant intended to restore appearance, support physiological loading, and accelerate osseointegration in a canine model.
A three-dimensional intact mandibular model of a beagle dog was reconstructed from cone-beam computed tomography scans. After virtual resection of a mandibular segment, the defect was replaced with a customized implant featuring a personalized external contour, internal supporting structures, and numerous micro-pores—all generated through topology optimization.
The authors used finite element method (FEM) analysis to compare the optimized implant with a non-optimized counterpart. Key biomechanical metrics included von Mises stress, displacement, and compliance under physiological loading conditions. The optimized design exhibited substantially lower peak stresses and displacements than the non-optimized model.
Topology optimization yielded a marked improvement in structural efficiency: implant compliance decreased by 53.3%, while weight was reduced by 37.2%. These gains indicate enhanced load transfer and stiffness with less material, a critical balance for mandibular function.
The optimized implant was fabricated using SLM with titanium alloy powder, validating manufacturability of the complex internal architectures. Measured implant weight closely matched predictions, supporting the feasibility of the design-to-print workflow.
The study concludes that topology-optimized, additively manufactured implants can achieve favorable biomechanical behavior while incorporating porous features to promote biological integration. This canine case study establishes a practical framework for personalized craniofacial implants with complex structures.
Source: Cheng, K.-J., Liu, Y.-F., Yao, C., Zhao, W., & Xu, X. (2019). A personalized mandibular implant with supporting and porous structures designed with topology optimization – a case study of canine. Rapid Prototyping Journal. Published March 4, 2019.
