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Design of Bone Plates for Mandibular Reconstruction Using Topology and Shape Optimization

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Advances in Structural and Multidisciplinary Optimization (WCSMO 2017)

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Abstract

Tumors in the maxillofacial area and cancer therapy in general can lead to necrosis of the lower jaw (mandible). To prevent tumor spread and infection the necrotic bone and surrounding soft tissue needs to be surgically removed. To restore normal function and appearance of the jaw, the resected mandible is reconstructed using autologous (originating within the body) bone graft from the fibula and titanium bone plates for the osteosynthesis (fixation) of the bone fragments.

Currently, standard bone plates are used that have a high volume or, in the case of mini plates, show a high risk of implant failure. The introduction of optimized, patient-specific bone plates helps to decrease intraoperative stress for the patient and facilitates an improved patient recovery by providing sufficient stabilization of the bone fragments as well as high stiffness and durability of the implants while minimizing the volume of the implanted material.

Within this publication, the design process of the topology optimized bone plates is shown. First, a finite element model of the reconstructed mandible was created using standardized, synthetic bone models, boundary conditions based on a custom made, biomechanical testing rig for the mandible and different biomechanical load cases. Then, the volumes of the initial design areas of the bone plates were reduced using topology optimization and the design of the final bone plates was developed including shape optimization.

Finally, a design validation of the optimized bone plate designs was conducted by a non-linear finite element analysis. A reduction of total volume of 44.9% was achieved by a maximum stress in the bone plates for the different load cases of 230.00 MPa to 797.10 MPa concluding high fatigue strength of the implants. The uneven load distribution over the screws of each bone plate could be reduced by up to 73.72% preventing overloading of one screw and thus reducing the risk of screw failure.

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Acknowledgements

The research project “TOPOS - Development, Manufacturing and Testing of Topology Optimized Osteosynthesis Plates” (AZ-1019-12), in whose context the presented study was conducted, is funded by the Bavarian Research Foundation (BFS). We thank the BFS for their excellent support.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Institute for Machine Tools and Industrial Management, Technical University of Munich, Munich, Germany

    Michael Seebach, Felix Theurer & Michael Friedrich Zaeh

  2. Department of Orthopaedics and Sports Orthopaedics, Technical University of Munich, Munich, Germany

    Peter Foehr, Constantin von Deimling & Rainer Burgkart

Authors
  1. Michael Seebach
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  2. Felix Theurer
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  3. Peter Foehr
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  4. Constantin von Deimling
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  5. Rainer Burgkart
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  6. Michael Friedrich Zaeh
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Corresponding author

Correspondence to Michael Seebach .

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Editors and Affiliations

  1. Chair for Optimization of Mechanical Stuctures, Faculty for Mechanical Engineering and Safety Engineering, University of Wuppertal, Wuppertal, Germany

    Axel Schumacher

  2. Institute for Construction Enginnering, Technische Universität Braunschweig, Braunschweig, Germany

    Thomas Vietor

  3. Braunschweig, Germany

    Sierk Fiebig

  4. Chair of Structural Analysis, Technische University of Munich, Munich, Germany

    Kai-Uwe Bletzinger

  5. Engineering Center, ECAE 197, University of Colorado Boulder, Boulder, Colorado, USA

    Kurt Maute

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Seebach, M., Theurer, F., Foehr, P., Deimling, C.v., Burgkart, R., Zaeh, M.F. (2018). Design of Bone Plates for Mandibular Reconstruction Using Topology and Shape Optimization. In: Schumacher, A., Vietor, T., Fiebig, S., Bletzinger, KU., Maute, K. (eds) Advances in Structural and Multidisciplinary Optimization. WCSMO 2017. Springer, Cham. https://doi.org/10.1007/978-3-319-67988-4_154

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  • DOI: https://doi.org/10.1007/978-3-319-67988-4_154

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  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-319-67987-7

  • Online ISBN: 978-3-319-67988-4

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