The reconstruction of large mandibular defects using commercial available reconstruction plates often leads to complications. The application of computer aided design technologies together with advanced medical imaging (CT/MRI) is gaining increased attention in reconstructive surgeries. Studies have proved that implants with porous structures can effectively enhances the biological fixation of the bone. However, no study has been reported on the design and analysis of the customized porous mandibular reconstruction.

The objective of this study is to present an integrated framework model for the design and analysis of customized porous reconstruction plate based on the selection of implant design techniques.

In this study two customized implant design techniques (mirroring/anatomical) are compared and the best design is selected based on the surface deviation. A 3D finite element analysis was performed on the selected implant design model to evaluate its biomechanical response under chewing conditions.

The finite element simulated results reveal that the designed porous plate can withstand the chewing load conditions and provides good stability. The maximum stresses developed on the reconstruction plate (360 MPa) and screws (122.90 MPa) are significantly less and within the failure limit of implant material.

Based on the results, it is recommended to use mirror design reconstruction technique in repair of mandibular bone which can effectively improve the stability and flexibility of mandibular reconstruction under chewing conditions.