Evaluation of Load and Stress Distribution for a Novel Design of Maxillary Protraction Facemask by Finite Element Analysis

<b>Background/Objectives:</b> Protraction facemasks are commonly used to treat Class III malocclusion in growing patients. Personalized facemasks designed using 3D modeling software and based on individual 3D face images are now available. This study aimed to assess the mechanical properties of three novel designs of Petit-type facemask appliances through three-dimensional Finite Element Analysis (FEA). <b>Methods</b>: Three novel designs of the facemask were modeled by Solidworks 3D CAD (2023): anatomic, V-shape, and arc-shape. FEA was performed by Ansys 2021 (R2) software. The elements' sizes, shapes, and numbers were identified, and the material property was set on Acrylonitrile butadiene styrene copolymer (ABS) plastic. The support and loading conditions of two different intensities of load, 7.8 and 9.8 N, respectively, were applied in three angulations to the occlusal plane: 0°, 30°, and 50°. Stress, strain, and total deformation results were obtained. <b>Results</b>: The minimum stress was reported with the anatomic design at a 30° angulation, whereas the maximum value was reported in the arc-shape design at 50°; however, there was no significant difference among the three designs. The von Mises yield criterion showed that the overall stresses were distributed on the larger areas of the facemask structure at 30° angulation for all designs. The stresses induced in all facemask appliance designs did not cause permanent deformation. <b>Conclusions</b>: Anatomic design has better mechanical behavour than the V-shape or arc shape design. Downward inclination of 30° to the occlusal plane induces less stress. These findings support the use of customized anatomic facemasks for the effective and efficient treatment of Class III malocclusions in growing patients, potentially improving clinical outcomes and patient comfort. Further research, particularly clinical trials, is needed to validate the results of the present study.