A Two-Scale Multi-Resolution Topologically Optimized Multi-Material Design of 3D Printed Craniofacial Bone Implants.

Bone replacement implants for craniofacial reconstruction require to provide an adequate structural foundation to withstand the physiological loading. With recent advances in 3D printing technology in place of bone grafts using autologous tissues, patient-specific additively manufactured implants are being established as suitable alternates. Since the stress distribution of these structures is complicated, efficient design techniques, such as topology optimization, can deliver optimized designs with enhanced functionality. In this work, a two-scale topology optimization approach is proposed that provides multi-material designs for both macrostructures and microstructures. In the first stage, a multi-resolution topology optimization approach is used to produce multi-material designs with maximum stiffness. Then, a microstructure with a desired property supplants the solid domain. This is beneficial for bone implant design since, in addition to imparting the desired functional property to the design, it also introduces porosity. To show the efficacy of the technique, four different large craniofacial defects due to maxillectomy are considered, and their respective implant designs with multi-materials are shown. These designs show good potential in developing patient-specific optimized designs suitable for additive manufacturing.

Topology optimization of fixed complete denture framework.

The functionality of a denture is directly related to the quality of life of the edentulous patients because treatment failure results in demoralizing consequences including difficulties in oral activities. Framework for fixed complete dentures plays a crucial role by transferring loads from the denture to the implants, which are integrated into the remaining bones and gingiva, thereby providing stability to the denture. Current techniques utilize 3D scan data of the implant site to capture the locations and soft tissue contours to design customized framework using computer-aided design (CAD) and computer-aided manufacturing (CAM) technology to properly support the denture teeth in their position. The performance and efficiency of these frameworks may be enhanced by incorporating a design optimization in the design process. We tested the feasibility of using the topology optimization to design patient-specific dental frameworks. The shapes of the optimized frameworks may be significantly different from the traditional designs, but better structural integrity is likely to be achieved with potentially less material. The numerical study reveals that commercially available dental framework would experience 16% less maximum stress when topology optimized even with a compliance minimization formulation with 50% volume fraction constraint. Topology optimization for designing dental frameworks might improve current clinical methods and provide better long-term patient satisfaction.

Design of complex bone internal structure using topology optimization with perimeter control.

Large facial bone loss usually requires patient-specific bone implants to restore the structural integrity and functionality that also affects the appearance of each patient. Titanium alloys (e.g., Ti-6Al-4V) are typically used in the interfacial porous coatings between the implant and the surrounding bone to promote stability. There exists a property mismatch between the two that in general leads to complications such as stress-shielding. This biomechanical discrepancy is a hurdle in the design of bone replacements. To alleviate the mismatch, the internal structure of the bone replacements should match that of the bone. Topology optimization has proven to be a good technique for designing bone replacements. However, the complex internal structure of the bone is difficult to mimic using conventional topology optimization methods without additional restrictions. In this work, the complex bone internal structure is recovered using a perimeter control based topology optimization approach. By restricting the solution space by means of the perimeter, the intricate design complexity of bones can be achieved. Three different bone regions with well-known physiological loadings are selected to illustrate the method. Additionally, we found that the target perimeter value and the pattern of the initial distribution play a vital role in obtaining the natural curvatures in the bone internal structures as well as avoiding excessive island patterns.

Designing patient-specific 3D printed craniofacial implants using a novel topology optimization method.

Large craniofacial defects require efficient bone replacements which should not only provide good aesthetics but also possess stable structural function. The proposed work uses a novel multiresolution topology optimization method to achieve the task. Using a compliance minimization objective, patient-specific bone replacement shapes can be designed for different clinical cases that ensure revival of efficient load transfer mechanisms in the mid-face. In this work, four clinical cases are introduced and their respective patient-specific designs are obtained using the proposed method. The optimized designs are then virtually inserted into the defect to visually inspect the viability of the design . Further, once the design is verified by the reconstructive surgeon, prototypes are fabricated using a 3D printer for validation. The robustness of the designs are mechanically tested by subjecting them to a physiological loading condition which mimics the masticatory activity. The full-field strain result through 3D image correlation and the finite element analysis implies that the solution can survive the maximum mastication of 120 lb. Also, the designs have the potential to restore the buttress system and provide the structural integrity. Using the topology optimization framework in designing the bone replacement shapes would deliver surgeons new alternatives for rather complicated mid-face reconstruction.

Experimental validation of 3D printed patient-specific implants using digital image correlation and finite element analysis.

With the dawn of 3D printing technology, patient-specific implant designs are set to have a paradigm shift. A topology optimization method in designing patient-specific craniofacial implants has been developed to ensure adequate load transfer mechanism and restore the form and function of the mid-face. Patient-specific finite element models are used to design these implants and to validate whether they are viable for physiological loading such as mastication. Validation of these topology optimized finite element models using mechanical testing is a critical step. Instead of inserting the implants into a cadaver or patient, we embed the implants into the computer-aided skull model of a patient and, fuse them together to 3D print the complete skull model with the implant. Masticatory forces are applied in the molar region to simulate chewing and measure the stress-strain trajectory. Until recently, strain gages have been used to measure strains for validation. Digital Image Correlation (DIC) method is a relatively new technique for full-field strain measurement which provides a continuous deformation field data. The main objective of this study is to validate the finite element model of patient-specific craniofacial implants against the strain data from the DIC obtained during the mastication simulation and show that the optimized shapes provide adequate load-transfer mechanism. Patient-specific models are obtained from CT scans. The principal maximum and minimum strains are compared. The computational and experimental approach to designing patient-specific implants proved to be a viable technique for mid-face craniofacial reconstruction.