Design and multi-objective optimization of mandibular implant models with additive manufacturing constraints

Abstract This project explored the manufacturability-driven design of mandibular reconstruction implant models made using extrusion-based additive manufacturing. A formalized multi-objective optimization framework was presented for the identification, collection, and mapping of the manufacturability constraints in the design model. This workflow ensures the manufacturability of the final product while also optimizing factors related to geometry, fit, structural integrity, material usage, and biocompatibility. This framework captured the realistic requirements driven by manufacturing processes to ensure that the final design could be manufactured. The method was demonstrated using a detailed case study that included the manufacturing and analysis of the final components and validation of the design, which clearly showed both the opportunities and limitations of engineering plastics for models. The case study results showed design success related to manufacturing, fit, material utility, and biocompatibility, but it was clear that the plastic models were not able to be used directly due to structural concerns. However, they proved to be excellent form/fit prototypes or casting forms for metal or ceramic implants. Common commercial software tools (Materialise Mimics, Autodesk Meshmixer, and nTop) were used throughout the process, making the method more accessible to practical users. This validated methodology will be useful both in the computer-aided design (CAD) and in medical device domains, as it allows the direct application of design-for-additive manufacturing principles during the design of custom implants. Unlike previous works, this design framework integrates manufacturability and performance constraints simultaneously. Graphical abstract