Data-Driven Design and Additive Manufacturing of Patient-Specific Lattice Titanium Scaffolds for Mandibular Bone Reconstruction

The reconstruction of segmental bone defects requires patient-specific scaffolds that combine mechanical safety, biological functionality, and rapid manufacturing. We converted CT-derived mandibular geometry into a functionally graded Ti-6Al-4V lattice and optimised porosity, screw layout, and strut thickness through a cyber-physical loop that joins high-fidelity FEM, millisecond ANN, and a BN for uncertainty quantification. Fifteen candidate scaffolds were fabricated by direct metal laser sintering and hot isostatic pressing and were mechanically tested. FEM predicted stress and stiffness with 98% accuracy; the ANN reproduced these outputs with 94% fidelity while evaluating 10,000 designs in real time, and the BN limited failure probability to <3% under worst-case loads. The selected 55–65% porosity design reduced titanium use by 15%, shortened development time by 25% and raised multi-objective optimisation efficiency by 20% relative to a solid-plate baseline, while resisting a 600 N bite with a peak von Mises stress of 225 MPa and micromotion < 150 µm. Integrating physics-based simulation, AI speed, and probabilistic rigour yields a validated, additively manufactured scaffold that meets surgical timelines and biomechanical requirements, offering a transferable blueprint for functional scaffolds in bone and joint surgery.