Comparative Evaluation of Symmetrical Titanium and Polyetheretherketone (PEEK) Hollow Structures for Mandibular Reconstruction: Strength, Geometry, and Biomechanical Performance

This study introduces a novel titanium hollow structure for mandibular reconstruction designed to optimize mechanical stability and stress distribution. A comparative evaluation with a similar polyetheretherketone (PEEK) structure is performed to assess material-specific biomechanical behavior. Methods: Finite element analysis (FEA) simulations were conducted to evaluate stress distribution, displacement, and structural stability of the symmetrical titanium and PEEK hollow structures under physiological conditions. The reconstructions were designed based on Scherk minimal surfaces, integrating fixing plates to achieve optimal mechanical performance while maintaining symmetry. Results: The FEA simulations demonstrated that the titanium hollow structure exhibited higher mechanical stability, lower displacement, and more uniform stress distribution, ensuring structural integrity under applied forces. In contrast, the PEEK structure displayed greater flexibility, which reduced stress shielding but resulted in higher deformation and lower load-bearing capacity. While titanium inherently supports osseointegration, PEEK requires surface modifications to enhance bone integration and long-term stability. Conclusions: The titanium hollow structure presents a promising advancement in metal-based mandibular reconstruction, effectively balancing strength, durability, and biological integration. Future research should focus on using more structures, enhancing surface modifications and optimizing lattice structures to further improve the biological and biomechanical performance of PEEK-based and titanium-based implants in load-bearing conditions.