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The purpose of this study is to obtain a titanium mandibular implant that possesses a personalized external shape for appearance recovery, a supporting structure for physiological loading and numerous micro-pores for accelerating osseointegration.

A three-dimensional intact mandibular model of a beagle dog was created from cone-beam computerized tomography scans. A segment of the lower jaw bone was resected and replaced by a personalized implant with comprehensive structures including a customized external shape, supporting structures and micro-pores, which were designed by topology optimization. Then with FEM analysis, the stress, displacement distribution and compliance of the designed implant were compared with the non-optimized model. The weight of the optimized implant that was fabricated by SLM with titanium alloy powder was measured and contrasted with the predicted non-optimized model for evaluating the viability of the design.

The FEM results showed the peaks of von Mises stress and displacement on the optimized implant were much lower than those of the implant without optimization. With topology optimization, the compliance of the implant decreased significantly by 53.3 per cent, and a weight reduction of 37.2 per cent could be noticed.

A design strategy for personalized implant, with comprehensive structures and SLM as the fabrication method, has been developed and validated by taking a canine mandible as the case study. With comprehensive structures, the implant presented good biomechanical behaviors thanks to the most appropriate supporting structures obtained by optimal design. The topological optimal design combined with SLM printing proved to be an effective method for the design and fabrication of personalized implant with complex structures.

The purpose of this study is to obtain an effective implant with porous structures on its surface, named porous-surfaced implant, which helps to improve the overall stability of the implant and promote the combination of implant and alveolar bone.

Porous-surfaced implants with a porosity of 16%, 21%and 32% were designed and the effect of porosity on the strength of the implant was analyzed by ABAQUS software. Porous-surfaced implants with different porosity were printed by selective laser melting and the surface morphology was observed. Animal experiments of implants with porous structures and coating were carried out in healthy beagle dogs. The experimental group was treated with hydroxyapatite coating and the control group was not treated. Bone volume (BV) and total volume (TV) of the implant surface of the experimental group and control group were calculated by Skyscan CTvol software.

With the increase of porosity of porous-surfaced implants, the neck stress of the porous-surfaced implants increased and their strength decreased. In addition, in animal vivo experiments, the ratio value of BV to TV of the porous-surfaced implants was between 55.38% and 79.86%, which was the largest when the porosity of porous-surfaced implants was 16%. The internal and surrounding bone formation content of porous-surfaced implants with hydroxyapatite coating was higher than porous-surfaced implants without coating.

The results of this study show that the pores on the surface of implants can be filled with the new bone and porous-surfaced implants with 16% porosity provide better space for the growth of new bone. The porous structures with hydroxyapatite coating are beneficial to the growth of new bone around implants. The results of this study are helpful to improve the overall stability of implants and to promote the combination of implant and alveolar bone.

The purpose of this paper was to find a successful treatment modality for patients suffering from temporomandibular joint (TMJ) ankylosis who could not be treated through traditional surgeries.

This work integrated the unique capabilities of the imaging technique, the rapid prototyping (RP) technology and the advanced manufacturing technique to develop the customised TMJ implant. The patient specific TMJ implant was fabricated using the computed tomography scanned data and the fused deposition modeling of RP for the TMJ surgery.

This approach showed good results in fabrication of the TMJ implant. Postoperatively, the patient experienced normalcy in the jaw movements.

Advanced technologies helped to fabricate the customised TMJ implant. The advantage of this approach is that the physical RP model assisted in designing the final metallic implant. It also helped in the surgical planning and the rehearsals.

This case report illustrates the benefits of imaging/computer‐aided design/computer‐aided manufacturing/RP to develop the customised implant and serve those patients who could not be treated in the traditional way.

The purpose of this study to investigate the organized porous network zinc (OPNZ) scaffolds. Their mechanical characteristics, surface roughness and fracture mechanism were assessed in relation to their structural properties. The prospects of fused deposition modeling (FDM) for printing metal scaffolds via rapid tooling have also been studied.

Zn scaffolds with different pore and strut sizes were manufactured via the rapid tooling method. This method is a multistep process that begins with the 3D printing of a polymer template. Later, a paraffin template was obtained from the prepared polymer template. Finally, this paraffin template was used to fabricate the Zn scaffold using microwave sintering. The characterization of prepared Zn samples involved structural characterization, microstructural study, surface roughness testing and compression testing. Moreover, based on the Gibson–Ashby model analysis, the model equations’ constant values were evaluated, which can help in predicting the mechanical properties of Zn scaffolds.

The scanning electron microscopy study confirmed that the fabricated sample pores were open and interconnected. The X-ray diffraction analysis revealed that the Zn scaffold contained hexagonal closed-packed Zn peaks related to the a-Zn phase, validating that scaffolds were free from contamination and impurity. The range for ultimate compressive strength, compressive modulus and plateau stresses for Zn samples were found to be 6.75–39 MPa, 0.14–3.51 GPa and 1.85–12.6 MPa by adjusting their porosity, which are comparable with the cancellous bones. The average roughness value for the Zn scaffolds was found to be 1.86 µm.

This research work can widen the scope for extrusion-based FDM printers for fabricating biocompatible and biodegradable metal Zn scaffolds. This study also revealed the effects of scaffold structural properties like porosity, pore and strut size effect on their mechanical characteristics in view of tissue engineering applications.

Digitalization and additive manufacturing now play an important role in the manufacturing of medical and dental products. The purpose of this paper is to present the results of the treatment of skeletal Class II malocclusion in a growing patient using fixed sagittal guidance (FSG) appliance manufactured by digital and fast procedure by selective laser melting.

This study present the case of a 14-year-old boy with a convex profile owing to a retrognathic mandible, an overjet (8 mm), a deep overbite (7 mm), a Class II canine, a molar relationship on both sides and an accentuated lower curve of Spee. The lateral cephalogram showed a skeletal Class II discrepancy with mandibular retrognathia, skeletal deep bite, reduced lower anterior facial height and proclined upper incisors. Treatment using FSG and fixed orthodontic appliance was performed within 15 months.

The final results show a well-balanced face and a nice profile. Protrusion of the maxillary anterior teeth was corrected, and a Class I molar relationship was achieved with proper overjet and overbite.

The results from the proposed method are promising, although long-term results with a large group are not yet available.

Using an individually made FSG appliance from biocompatible material and an individualized treatment plan, an effective result in treating Class II malocclusion due to retrognathic mandible with favorable dentofacial effects has been achieved.

This is the first paper describing the use of additive manufacturing for orthodontic appliances in Slovenia.

The computer‐aided design (CAD) and manufacture of custom‐fitting surgical guides have been shown to provide an accurate means of transferring computer‐aided planning to surgery. To date guides have been produced using fragile materials via rapid prototyping techniques such as stereolithography (SLA), which typically require metal reinforcement to prevent damage from drill bits. The purpose of this paper is to report case studies which explore the application of selective laser melting (SLM) to the direct manufacture of stainless steel surgical guides. The aim is to ascertain whether the potential benefits of enhanced rigidity, increased wear resistance (negating reinforcement) and easier sterilisation by autoclave can be realised in practice.

A series of clinical case studies are undertaken utilising medical scan data, CAD and SLM. The material used is 316L stainless steel, an alloy typically used in medical and devices and surgical instruments. All treatments are planned in parallel with existing techniques and all guides are test fitted and assessed on SLA models of the patients' anatomy prior to surgery.

This paper describes the successful application of SLM to the production of stainless steel surgical guides in four different maxillofacial surgery case studies. The cases reported address two types of procedure, the placement of osseointegrated implants for prosthetic retention and Le Fort 1 osteotomies using internal distraction osteogenesis. The cases reported here have demonstrated that SLM is a viable process for the manufacture of custom‐fitting surgical guides.

The cases have identified that the effective design of osteotomy guides requires further development and refinement.

This paper represents the first reported applications of SLM technology to the direct manufacture of stainless steel custom‐fitting surgical guides. Four successful exemplar cases are described including guides for osteotomy as well as drilling. Practical considerations are presented along with suggestions for further development.

Chest wall reconstruction of large oncological defects following resection is challenging. Traditional management involves the use of different materials that surgeons creatively shape intraoperatively to restore the excised anatomy. This is time-consuming, difficult to mould into shape and causes some complications such as dislocation or paradoxical movement. This study aims to present the development and clinical implantation of a novel custom-made three-dimensional (3D) laser melting titanium alloy implant that reconstructs a large chest wall resection and maintains the integrity of the thoracic cage.

The whole development process of the novel implant is described: design specifications, computed tomography (CT) scan manipulation, 3D computer-assisted design (CAD), rapid prototyping, final manufacture and clinical implantation. A multidisciplinary collaboration in between engineers and surgeons guided the iterative design process.

The implant provided excellent aesthetical and functional results. The virtual planning and production of the implant prior to surgery reduced surgery time and uncertainty. It also improved safety and accuracy. The implant sited nicely on the patient anatomy after resection following the virtual plan. At six months following implantation, there were no implant-related complications of pain, infection, dislocation or paradoxical movement. This technique offered a fast lead-time for implant production, which is crucial for oncological treatment.

More cases and a long-term follow-up are needed to confirm and quantify the benefits of this procedure; further research is also required to design a solution that better mimics the chest wall biomechanics while preventing implant complications.

The authors present a novel custom thoracic implant that provided a satisfactory reconstruction of a large chest wall defect, developed and implanted within three weeks to address a fast-growing chondrosarcoma. Furthermore, the authors describe its development process in detail as a design guideline, discussing potential improvements and critical design considerations so that this study can be replicated for future cases.

In the past decade, three-dimensional (3D) printing has gained attention in areas such as medicine, engineering, manufacturing art and most recently in education. In biomedical, the development of a wide range of biomaterials has catalysed the considerable role of 3D printing (3DP), where it functions as synthetic frameworks in the form of scaffolds, constructs or matrices. The purpose of this paper is to present the state-of-the-art literature coverage of 3DP applications in tissue engineering (such as customized scaffoldings and organs, and regenerative medicine).

This review focusses on various 3DP techniques and biomaterials for tissue engineering (TE) applications. The literature reviewed in the manuscript has been collected from various journal search engines including Google Scholar, Research Gate, Academia, PubMed, Scopus, EMBASE, Cochrane Library and Web of Science. The keywords that have been selected for the searches were 3 D printing, tissue engineering, scaffoldings, organs, regenerative medicine, biomaterials, standards, applications and future directions. Further, the sub-classifications of the keyword, wherever possible, have been used as sectioned/sub-sectioned in the manuscript.

3DP techniques have many applications in biomedical and TE (B-TE), as covered in the literature. Customized structures for B-TE applications are easy and cost-effective to manufacture through 3DP, whereas on many occasions, conventional technologies generally become incompatible. For this, this new class of manufacturing must be explored to further capabilities for many potential applications.

This review paper presents a comprehensive study of the various types of 3DP technologies in the light of their possible B-TE application as well as provides a future roadmap.

Medical devices are undergoing rapid changes because of the increasing affordability of advanced technologies like additive manufacturing (AM) and three-dimensional scanning. New avenues are available for providing solutions and comfort that were not previously conceivable. The purpose of this paper is to provide a comprehensive review of the research on developing prostheses using AM to understand the opportunities and challenges in the domain. Various studies on prosthesis development using AM are investigated to explore the scope of integration of AM in prostheses development.

A review of key publications from the past two decades was conducted. Integration of AM and prostheses development is reviewed from the technologies, materials and functionality point of view to identify challenges, opportunities and future scope.

AM in prostheses provides superior physical and cognitive ergonomics and reduced cost and delivery time. Patient-specific, lightweight solutions for complex designs improve comfort, functionality and clinical outcomes. Compared to existing procedures and methodologies, using AM technologies in prosthetics could benefit a large population.

This paper helps investigate the impact of AM and related technology in the field of prosthetics and can also be viewed as a collection of relevant medical research and findings.

The purpose of this paper is to present the methodology of a design process of new lumbar intervertebral disc implants with specific emphasis on the use of rapid prototyping technologies. The verification of functionality of artificial intervertebral discs is also given. The paper describes the attempt and preliminary research to evaluate the properties of the intervertebral disc implant prototypes manufactured with the use of different rapid prototyping technologies, i.e. FDM – fused deposition modelling, 3DP – 3D printing and SLM – selective laser melting.

Based on the computed tomography (CT) scan data, the anatomical parameters of lumbar spine bone tissue were achieved, which were the bases for the design-manufacture process carried out with the use of computer-aided designing/computer-aided engineering/computer-aided manufacturing systems. In the intervertebral disc implant design process, three RP technologies: FDM, 3DP and SLM were used for solving problems related to the reconstruction of geometry and functionality of the disc. Some preliminary tests such as measurement of roughness and structural analyses of material of prototypes made by different prototyping technologies were performed.

This paper allowed the authors to elaborate and patent two new intervertebral disc implants. Because the implant designs are parametrical ones with relation to lumbar bone tissue properties measured on CT scans, they can be also made for individual patients. We also compared some of the properties of intervertebral implants prototypes made with the use of FDM, 3DP and SLM technologies.

The paper presents the new intervertebral disc implants and their manufacturing by rapid prototyping. The methodology of designing intervertebral disc implant is shown. Some features of the methodology make it useful for preoperative planning of intervertebral disc surgery, as well.