Craniofacial reconstruction using 3D personalized implants with enhanced surface properties: Technological and clinical aspects

Abstract

In this study, the modification of personalized titanium implants was developed using the plasma electrolytic oxidation process. Plasma electrolytic oxidation process parameters were initially optimized using solid samples of the Ti6Al4V alloy. Oxidation was achieved in an electrolyte containing calcium and phosphorus compounds at 250 V. The oxide layer produced was characterized by the use of human osteoblasts and fibroblasts, with high biological activity of the modified titanium alloy in relation to these cells was demonstrated. Based on tomographic examinations, models were made and then personalized implants for three patients were printed from a Ti6Al4V alloy powder. These implants were subjected to plasma electrolytic oxidation treatment within the previously developed parameters and surgically placed in the craniofacial area. On the basis of postoperative studies, surgical interventions were successful, with modification of the surface using the plasma electrolytic oxidation method producing bioactive surfaces for both bone and soft tissue.

Keywords

• Craniofacial implants
• 3D printing
• Personalized implants
• Ti alloy
• Plasma electrolytic oxidation