Advancing dental surgical training with biomimetic lattice reinforcement in polyjet-printed models

Realistic soft-tissue behaviour is essential for surgical training, yet most additively manufactured models remain mechanically homogeneous. The purpose of this study was to investigate whether embedding biomimetic lattice architectures within standard PolyJet elastomers can improve the haptic and biomechanical realism of dental suturing models. Seven different biomimetic lattice geometries: circular, cubic, donut, C-shaped, H-shaped, L-shaped (stretcher), and H-shaped (grid) were integrated into flexible polymer matrices via PolyJet printing, six replicates per lattice. The reinforced models underwent suture pull-out, three-point bending, and durometer tests to compare elasticity, suture retention, and surface roughness with those of non-reinforced specimens. A dental surgical simulation model incorporating the cubic lattice was fabricated and evaluated using a visual analogue scale (VAS). Lattice reinforcement significantly improved mechanical performance versus plain prints across tests. The cubic lattice showed the most favourable overall profile, achieving the highest suture pull-out force (5.16 ± 0.34 N), increased bending modulus (7.31 ± 0.07 MPa vs 1.70 ± 0.09 MPa for plain), and greater hardness (Shore A 66.3–66.5 vs 28.9 ± 1.26 for plain). Surface roughness was markedly reduced in lattice-reinforced specimens (e.g., ~87–107 µm for cubic/circular/H-grid) compared with plain (~511 ± 129 µm). The dental suture simulation model produced lifelike penetration resistance and knot security. Embedding biomimetic lattices into PolyJet materials yields enhanced biomechanics and haptics without resorting to expensive polymers. The cubic lattice performed best overall and informed the final model design. This cost-effective approach can augment surgical skills while reducing reliance on cadaveric or animal models.