Conventional mandibular reconstruction frequently results in stress shielding, compromised osteotomy site healing, or bone resorption. This study introduces an Embedded Polygonal Bone Reconstruction Structure (EPBRS) that eliminates titanium plate dependency, enhanced through fillet-based topological optimization.

A computational model of the Embedded Polygonal Bone Reconstruction Structure (EPBRS) was developed from CT scans. Four variants with fillet radii (0.2, 0.4, 0.6, and 0.8 mm) were designed. Physiological masticatory loading was simulated under identical conditions. The values of the von Mises stress and peak displacements were calculated for all configurations.

With increasing fillet radius: The Maximum von Mises stress in the fibula graft decreased from 87.21 MPa to 37.59 MPa. The Maximum von Mises stress in the mandible decreased from 100.73 MPa to 23.9 MPa. The Maximum von Mises stress in titanium screws remained statistically invariant (170–185 MPa). Peak displacement (fibula graft, screws, mandible) decreased by approximately 0.1 mm between 0 mm and 0.2 mm fillet radii, remaining stable with further increases

The embedded polygonal reconstruction demonstrates significant biomechanical safety and reliability. Fillet optimization substantially reduced the Maximum von Mises stress and improved deformation resistance.