3D printing of asymmetric buttress plate for posteromedial tibial plateau fracture using metal fused filament fabrication

Purpose - This research addresses the challenges encountered when securing bone plates in the human body to treat tibial plateau fractures, specifically focusing on preventing posterolateral fractures. The goal is to develop a 3D buttress plate that offers better stability, facilitating anatomical reduction and rigid fixation. The newly fabricated T-buttress plate enables early knee motion and reduces postoperative complications, marking a significant advancement over existing internal fixation plates. Design/methodology/approach - A new buttress plate model was designed using modeling software, featuring an asymmetric curved design with three fragments. Finite element analysis was used to simulate the biomechanical performance of this new model, comparing it with symmetric flat and symmetric curved plates. Accurately predicting the biomechanical behavior of the implant posed challenges, especially during extensive simulations. Optimal parameters for the asymmetric curved plate were identified from the simulation results, and the 3D buttress plate was then fabricated using the metal fused filament fabrication (MFFF) process. This process presents challenges due to the novel nature of the asymmetric design. Findings - The results indicate that the newly developed buttress plate exhibits superior strength and performance compared to current internal fixation plates. Biomechanical simulations show that the asymmetric curved design provides better stability and support. Moreover, the yield and ultimate tensile strengths were found to be 685 MPa and 855 MPa, respectively. Research limitations/implications - The study's finite element analysis model has limitations due to its reliance on assumptions about material properties, boundary conditions and loading scenarios. It also excludes biological factors, patient variability and the bone's heterogeneous nature, which may affect the accuracy and applicability of the results in real-life situations. Originality/value - The development of an asymmetric curved buttress plate using MFFF is a novel innovation aimed at improving biomechanical performance and patient outcomes in orthopedic surgery, offering significant potential impact in the medical field.