Analysis of biomechanical behavior of 3D printed mandibular graft with porous scaffold structure designed by topological optimization

Our long-term goal is to design and manufacture a customized graft with porous scaffold structure for repairing large mandibular defects using topological optimization and 3D printing technology. The purpose of this study is to characterize the mechanical behavior of 3D printed anisotropic scaffolds as bone analogs by fused deposition modeling (FDM). Methods: Cone beam computed tomography (CBCT) images were used to reconstruct a 3D mandible and finite element models. A virtual sectioned-block of the mandible was used as the control group and the trabecular portion of the block was modified by topological optimization methods as experimental groups. FDM (FDM) printed samples at 0, 45 and 90 degrees with Poly-lactic acid (PLA) material under a three-point bending test. Finite element analysis was also used to validate the data obtained from the physical model tests. Results: The ultimate load, yield load, failure deflection, yield deflection, stress, strain distribution, and porosity of scaffold structures were compared. The results show that the topological optimized graft had the best mechanical properties. Conclusions: The results from mechanical tests on physical models and numerical simulations from this study show a great potential for topological optimization and 3D printing technology to be served in design and rapidly manufacturing of artificial porous grafts.