Customized porous implants by additive manufacturing for zygomatic reconstruction

Abstract Background Moderate to severe facial esthetic problems challenge the surgeons to discover alternate ways, to rehabilitate the patients using customized porous designs. Porous metal implants are available for over 30 years, but the pore architecture, is constantly changing to improve the stability and longevity of the implant. Objective To evaluate a customized porous implant produced from electron beam melting and to restore the zygomatic functionality. Methods Two customized zygomatic reconstruction implants-bulk and porous, are designed based on the bone contours and manufactured using state of art-electron beam melting technology. The two designed implants are evaluated based on strength, weight and porosity for the better osseointegration and rehabilitation of the patient. Results Porous structures due to their light weight, low volume and high surface area provided better specific strength and young's modulus closer to the bone. Microscopic and CT scanning confirmed that the EBM produced porous structures are highly regular and interconnected without any major internal defects. Conclusions The customized porous implants satisfies the need of lighter implants with an adequate mechanical strength, restoring better functionality and esthetic outcomes for the patients.