Mechanical Fatigue Performance of Patient-Specific Polymer Plates in Oncologic Mandible Reconstruction

Comparative Evaluation of Symmetrical Titanium and Polyetheretherketone (PEEK) Hollow Structures for Mandibular Reconstruction: Strength, Geometry, and Biomechanical Performance

This study introduces a novel titanium hollow structure for mandibular reconstruction designed to optimize mechanical stability and stress distribution. A comparative evaluation with a similar polyetheretherketone (PEEK) structure is performed to assess material-specific biomechanical behavior. Methods: Finite element analysis (FEA) simulations were conducted to evaluate stress distribution, displacement, and structural stability of the symmetrical titanium and PEEK hollow structures under physiological conditions. The reconstructions were designed based on Scherk minimal surfaces, integrating fixing plates to achieve optimal mechanical performance while maintaining symmetry. Results: The FEA simulations demonstrated that the titanium hollow structure exhibited higher mechanical stability, lower displacement, and more uniform stress distribution, ensuring structural integrity under applied forces. In contrast, the PEEK structure displayed greater flexibility, which reduced stress shielding but resulted in higher deformation and lower load-bearing capacity. While titanium inherently supports osseointegration, PEEK requires surface modifications to enhance bone integration and long-term stability. Conclusions: The titanium hollow structure presents a promising advancement in metal-based mandibular reconstruction, effectively balancing strength, durability, and biological integration. Future research should focus on using more structures, enhancing surface modifications and optimizing lattice structures to further improve the biological and biomechanical performance of PEEK-based and titanium-based implants in load-bearing conditions.

A Comparative Finite Element Analysis of Titanium, Autogenous Bone, and Polyetheretherketone (PEEK)-Based Solutions for Mandibular Reconstruction

Mandibular reconstruction is essential for restoring both function and aesthetics after segmental resection due to tumoral pathology. This study aimed to conduct a comparative analysis of three reconstruction strategies for defects resulting from segmental mandibular resection, utilizing finite element analysis (FEA).

METHODS

A digital model of the mandible was created from CBCT data and optimized for FEA. Three reconstruction scenarios were simulated: fixation with a titanium plate, reconstruction with an autogenous fibular graft stabilized with the same titanium plate, and fixation with a customized PEEK plate. Various plate thicknesses were analyzed to determine the stress and deformation patterns under masticatory loads.

RESULTS

Titanium plates provided superior mechanical stability but showed stress concentrations near screw fixation points. The addition of autogenous bone grafts reduced stress on the plate and improved structural integrity. PEEK plates exhibited reduced stress shielding and better load distribution, but thinner designs were prone to deformation. Minimum recommended thicknesses of 1.2 mm for titanium plates and 1.8 mm for PEEK plates were identified by FEA.

CONCLUSIONS

This study highlights the importance of material selection and patient-specific design in mandibular reconstruction. Autogenous bone grafts combined with titanium plates demonstrated the best biomechanical outcomes, while PEEK plates offer a promising alternative, particularly for patients where grafting is contraindicated.

A non-metallic PEEK topology optimization reconstruction implant for large mandibular continuity defects, validated using the MANDYBILATOR apparatus

In cases of large mandibular continuity defects resulting from malignancy resection, the current standard of care involves using patient-specific/custom titanium reconstruction plates along with autogenous grafts (fibula, scapula, or iliac crest segments). However, when grafts are not feasible or desired, only the reconstruction plate is used to bridge the gap. Unfortunately, metal osteosynthesis and reconstruction plates, including titanium, exhibit adverse effects such as stress-shielding and limitations in accurate postoperative irradiation (especially with proton-beam therapy). To address these issues, in this study we explore, develop and validate a non-metallic solution: a topology-optimized polyetheretherketone (PEEK) load-bearing implant for large non-grafted mandibular continuity defects. In order to thoroughly validate the developed PEEK reconstruction, a dedicated MANDYBILATOR testing apparatus was developed. Using the MANDYBILATOR finite element analysis results of the implant were confirmed and the PEEK implant was mechanically validated for both static and dynamic loading. Results show that the PEEK reconstructed mandible is comparably strong as the unreconstructed mandible and is unlikely to fail due to fatigue. Our PEEK implant design has the mechanical potential to act as a substitute for the current titanium plates used in the reconstruction of continuity defects of the mandible. This may potentially lead to optimised patient-specific reconstructions, with the implants matching the bone's stiffness and possessing radiolucent properties which are useful for radiographic follow-ups and radiotherapy. Furthermore, the addition of the dynamic/cyclic MANDYBILATOR apparatus allows for more realistic application of the in-vivo loading of the mandible and can provide added insights in biomechanical behaviour of the mandible.

Template based segmental mandibulectomy with nerve preservation and patient-specific PEEK plate reconstruction in a dog

A 7-year-old French Bulldog presented with an acanthomatous ameloblastoma affecting approximately 30% of the right mandibular body. We utilized a patient-specific 3D-printed surgical template to perform lateral fenestration of the mandible and elevation of the inferior alveolar nerve (IAN), facilitating nerve preservation during subsequent segmental mandibulectomy. The resulting critical-sized bone defect was anatomically stabilized using a patient-specific polyetheretherketone (PEEK) bridging plate. The recovery process was uneventful, with maintained occlusion and orofacial sensitivity.Similar to cases in humans with ameloblastoma, preserving orofacial sensitivity through the preservation of the inferior alveolar nerve seems feasible in dogs. Consequently, potential negative consequences of permanent regional denervation, which are unavoidable in traditional mandibulectomy, can be avoided. Bridging the ostectomy with a PEEK plate, offering advantages such as radiolucency, absence of imaging artifacts, and a modulus of elasticity similar to bone, proved to be functional in this canine patient, with no signs of complications observed up to the latest follow-up at 6 months.

Potential of photon counting computed tomography derived spectral reconstructions to reduce beam-hardening artifacts in chest CT

PURPOSE

Aim of the recent study is to point out a method to optimize quality of CT scans in oncological patients with port systems. This study investigates the potential of photon counting computed tomography (PCCT) for reduction of beam hardening artifacts caused by port-implants in chest imaging by means of spectral reconstructions.

METHOD

In this retrospective single-center study, 8 ROIs for 19 spectral reconstructions (polyenergetic imaging, monoenergetic reconstructions from 40 to 190 keV as well as iodine maps and virtual non contrast (VNC)) of 49 patients with pectoral port systems undergoing PCCT of the chest for staging of oncologic disease were measured. Mean values and standard deviation (SD) Hounsfield unit measurements of port-chamber associated hypo- and hyperdense artifacts, bilateral muscles and vessels has been carried out. Also, a structured assessment of artifacts and imaging findings was performed by two radiologists.

RESULTS

A significant association of keV with iodine contrast as well as artifact intensity was noted (all p < 0.001). In qualitative assessment, utilization of 120 keV monoenergetic reconstructions could reduce severe and pronounced artifacts completely, as compared to lower keV reconstructions (p < 0.001). Regarding imaging findings, no significant difference between monoenergetic reconstructions was noted (all p > 0.05). In cases with very high iodine concentrations in the subclavian vein, image distortions were noted at 40 keV images (p < 0.01).

CONCLUSIONS

The present study demonstrates that PCCT derived spectral reconstructions can be used in oncological imaging of the thorax to reduce port-derived beam-hardening artefacts. When evaluating image data sets within a staging, it can be particularly helpful to consider the 120 keV VMIs, in which the artefacts are comparatively low.

Metallic Artifact Reduction in Midfacial CT Scans Using Patient-Specific Polymer Implants Enhances Image Quality

Midfacial reconstruction after tumor resection surgery is commonly conducted by using autologous bone grafts or alloplastic implants. Titanium is the most frequently used osteosynthesis material in these cases but causes disturbing metallic artifacts in CT imaging. The purpose of this experimental study was to evaluate whether the use of midfacial polymer implants reduces metallic artifacts in CT imaging to improve image quality. Zygomatic titanium (n = 1) and polymer (n = 12) implants were successively implanted in a human skull specimen. Implants were analyzed for their effect on Hounsfield Unit values (streak artifacts) and virtual growth in CT images (blooming artifacts) as well as image quality. Multi-factorial ANOVA and Bonferroni's post hoc test were used. Titanium (173.7 HU; SD ± 5.1) and hydroxyapatite containing polymers (155.3 HU; SD ± 5.9) were associated with significantly more streak artifacts compared to all other polymer materials. There was no significant difference in blooming artifacts between materials. The metallic artifact reduction algorithm showed no significant difference. Image quality was slightly better for polymer implants compared to titanium. Personalized polymer implants for midfacial reconstruction significantly reduce metallic artifacts in CT imaging which improves image quality. Hence, postoperative radiation therapy planning and radiological tumor aftercare around the implants are facilitated.

Plasma Electrolytic Polished Patient-Specific Orbital Implants in Clinical Use-A Technical Note

This technical note describes the technique of plasma electrolytic polishing on orbital patient-specific implants and demonstrates clinical handling and use by the insertion of a plasma electrolytic polished orbital implant into a patient.