Standardized Morphological Modeling and Simulation-Based Validation of a Novel Tibiotalar Fusion Implant

This study establishes a standardized geometric model of the tibiotalar joint based on anatomical morphology and validates its statistical representativeness. Using this model, a novel fusion implant was developed and evaluated for its biomechanical performance through nonlinear finite element (FE) analysis compared to traditional fixation methods. A morphological database of the tibiotalar joint was built using 30 computed tomography (CT) scans to determine key dimensional parameters, and a novel fusion implant was designed to match the joint's natural curvature. FE analysis compared three fixation strategies: (1) the novel implant with an anterior plate, (2) the anterior plate alone, and (3) three compression screws. Biomechanical parameters, including joint contact area, micromotion, and stress distribution, were analyzed under simulated loading conditions. The novel implant achieved the highest joint contact area (95.0%) and lowest tibial micromotion (0.033 mm), significantly reducing stress concentration compared to anterior plate fixation (49.8% contact; 0.068 mm micromotion) and compression screws (78.2% contact; 0.355 mm micromotion). Constructing a standardized tibiotalar joint model with verified normal distribution is crucial for ensuring broad implant applicability. FE analysis demonstrated that the novel implant enhances joint contact, reduces micromotion, and optimizes stress distribution, offering a promising approach for improving surgical outcomes in tibiotalar joint fusion.