Biomechanical evaluation of 3D-printed porous lattice versus solid mandibular implants: an in vitro study

Segmental mandibular reconstruction is challenging. This in-vitro study compared the biomechanics of two 3D-printed porous Ti-6Al-4 V implants (Quad-diametral-cross, Hex-vase) versus a solid implant using a dual-material 3D-printed mandibular model and strain gauges. A 100 N static load was applied. Under eccentric loading, the solid implant generated extremely high tensile strain (871.67 µε), while porous designs reduced peak strains. The Hex-vase design transmitted the highest compressive strain (-795.85 µε), 65% greater in magnitude than the solid, suggesting improved mechanical stimulus transfer to peri-implant bone. The QDC design provided a moderate environment, suitable for compromised bone. Porous implants are biomechanically superior, offering customizable solutions to mitigate stress shielding.