Computational modelling and optimization of porous plates for mandibular fracture fixation accounting for bone healing

Appropriate fixation is critical for mandibular fracture healing, as it enhances biomechanical stability. This study assessed the impact of fixation techniques and bone plate designs on angle mandible fractures, aiming to optimize healing processes and maintain structural integrity under varied conditions. Five distinct bone plates were assessed: conventional one dense bone plate (1 DP), two dense bone plates (2 DP), two porous plates (2 PP), a topology-optimized bone plate (OBP), and two modified porous bone plates (2 MPP), while the volume was constrained to 160 mm³ for the designs 2 PP, OBP, and 2 MPP. Four different fracture gaps were considered (e.g. 0.5, 1.0, 1.5, and 2.0 mm) and assembled with titanium bone plates and analyzed under chewing loads. The healing process was predicted using a mechano-regulation algorithm. Conventional plate showed excessive interfragmentary strain (IFS) of approximately 1.4 and 0.6 in the 0.5 mm and 2.0 mm fracture gaps, respectively, which resulted in delayed healing. 2 MPP bone plates exhibited improved biomechanical performance with less stress in the bone plates and improved micromovement at the fracture site, promoting early bone union. The results have the potential to impact maxillofacial surgery by providing potential bone plate designs, ultimately improving patient outcomes and reducing recovery time.