Feasibility of Integrating Locking Plate System into Additively Manufactured Implants: A Mechanical Comparison of Three-Dimensional-Printed and Machined Locking Hole Threads
🔍 Key Findings
- Directly 3D-printed locking plate holes can achieve mechanical performance comparable to machined plates when printed at optimal orientation (0°).
- All 3D-printed plates failed at 2.0 Nm insertion torque due to thread deformation, while machined ARIX plates tolerated this torque without failure.
- Build orientation significantly affected mechanical strength, with push-out strength ranking: ARIX > 3D-0° > 3D-45° > 3D-90°.
- Insertion torque was a major determinant of push-out strength, with 1.1 Nm (manufacturer-recommended torque) producing the highest strength.
- Low torque combined with screw angulation (15°) resulted in the lowest push-out strength, demonstrating reduced screw–plate engagement.
- Screw angulation alone did not significantly reduce strength when torque was adequate, likely due to the ARIX double-lead thread design allowing engagement up to 15°.
- Additive manufacturing produced threads with lower hardness compared with machined threads, explaining deformation at excessive torque.
- Integrated 3D-printed locking systems may enable patient-specific implants without post-machining, potentially improving implant conformity and surgical efficiency.
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🔍 Key Findings
- Directly 3D-printed locking plate holes can achieve mechanical performance comparable to machined plates when printed at optimal orientation (0°).
- All 3D-printed plates failed at 2.0 Nm insertion torque due to thread deformation, while machined ARIX plates tolerated this torque without failure.
- Build orientation significantly affected mechanical strength, with push-out strength ranking: ARIX > 3D-0° > 3D-45° > 3D-90°.
- Insertion torque was a major determinant of push-out strength, with 1.1 Nm (manufacturer-recommended torque) producing the highest strength.
- Low torque combined with screw angulation (15°) resulted in the lowest push-out strength, demonstrating reduced screw–plate engagement.
- Screw angulation alone did not significantly reduce strength when torque was adequate, likely due to the ARIX double-lead thread design allowing engagement up to 15°.
- Additive manufacturing produced threads with lower hardness compared with machined threads, explaining deformation at excessive torque.
- Integrated 3D-printed locking systems may enable patient-specific implants without post-machining, potentially improving implant conformity and surgical efficiency.
Simini Surgery Review Podcast
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