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International Research Journal of Modernization in Engineering Technology and Science

Volume:02/Issue:11/November -2020 Impact Factor- 5.354 www.irjmets.com
BIO- MODELLING AND ADDITIVE MANUFACTURING OF HUMAN

MANDIBLES AND FEA ANALYSIS OF DENTAL IMPLANTS FOR
PROSTHODONTIC APPLICATIONS
Jaya Prakash kojjanakodaka *1
*1Student, Department of Mechanical Engineering, GITAM University, Vizag, India.
ABSTRACT
This study mainly deals with the role of Additive Manufacturing and FEA in the field of implant dentistry.
For the patients having missing teeth the methods of taking impressions from the actual teeth present in
the mouth and the implantation procedure became a tedious task by using conventional methods. To
solve these problems, digital manufacturing is come into existence. In this study, data of patients aged 53
were considered as (Case 1) and data for 26-year-old patient were considered as (Case 2) having first
molar missing teeth on the mandible with no health complications and issues are chosen to carry the
work.
Patient data is obtained with the help of CBCT Scan (Cone Beam computerized Tomography). CBCT
consists of raw data and noise factors, so it is very important to post process the scanned data, prior to
the Additive Manufacturing of bio models. For bio-modelling In Vesalius medical software is used to
process and extract data from the CBCT DICOM format to the Rapid Prototyping STL format. After
processing, STL errors is corrected in Autodesk Netfabb and Autodesk Meshmixer to further create error-
free STL files of the mandibles belongs to the two patients which are chosen to carry the work.
Keywords: CBCT Scan, FEA.
I. INTRODUCTION
Fused Deposition Modelling (FDM) technique is used to print the bio-models of both the mandibles. The
real time physical models of the mandibles for both the patients are obtained with the help of the FDM
technique used. Detailed anatomy can be studied with the help of the physical models obtained and dental
surgeons can perform mock-surgery before the implant placement to increase the success rates of the
surgery.
The rapid prototyping mandible STL files attained from both the cases is further converted to STEP files
(Standard for the exchange of Product Data) and performed FEA Analysis of the implant placement on the
missing teeth area. Insertion torque and Occlusal force are determined by using Implant Genesis Aktiv
Implants for both the patients selected as Case-1 & 2. The maximum deformation obtained for insertion
torque of 400 N-mm for case-1 is 0.0065121mm and for case-2 it is 0.015658mm which is very low and
permissible to the jaw bone. The maximum von-mises stress attained for Case-1 from the insertion torque
of 300 N-mm is 65.12 Mpa, insertion torque of 350 N-mm is 75.98 Mpa, and for insertion torque of 400 N-
mm is 86.837 Mpa. The maximum von-mises stress obtained for Case-2 from the insertion torque of 300
N-mm is 78.73 Mpa, insertion torque of 350 N-mm is 91.85 Mpa, and for insertion torque of 400 N-mm is
104.98 Mpa. The results obtained by performing the analysis shows that the Von-mises stress distribution
to the jaw bone is permissible and acceptable for the implant stability for the three torque loads selected
for both the cases.
The implant used for Case-1 is having 5mm diameter and a length of 11.5 mm; the implant used in Case-2
had a diameter of 5 mm and a length of 8 mm, which was simulated using FEA in the first molar area. The
total deformation maximum obtained for the occlusal force for maximum bite force of 76N is
0.024468mm for case-1 and 0.0097491mm for case-2 which is acceptable for the bone and the implant
The von-mises stress attained from the first molar occlusal force of 24N, 50N and 76N for Case-1 is 21.69
Mpa, 45.19 Mpa and 68.69 Mpa, and for Case-2 the von-mises stress attained for occlusal force of 24N,
50N and 76N is 18.89 Mpa, 39.35 Mpa and 59.81 Mpa. The maximum occlusal load of 120N is taken from
the literature for the further assessment of stress distribution by chewing different kinds of hard foods.
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The total deformation obtained for the maximum occlusal force of 120N is 0.038634mm and the Von-
mises stress obtained is 108.46 Mpa for case-1, and for case-2 the deformation obtained is 0.015393mm
and von- mises stress is 94.449 Mpa which shows that the stress distributions are acceptable.
For each product, Factor of Safety is important to assess the failure of the product. The Factor of Safety is
done for both fixture and abutment since the fixture is made of titanium grade 4 and abutment is made of
titanium grade 5. The factor of safety attained for the maximum occlusal load of 76N for Case-1 is 7 for
fixture made of titanium grade 4 and Factor of Safety of 11 is obtained for implant abutment made of
titanium grade 5. For Case-2 the Factor of Safety attained for fixture is 8 and for abutment. The maximum
occlusal load of 120N is taken from the literature for the further assessment of Factor of Safety after
chewing of various hard foods. After performing analysis of maximum occlusal load of 120N the Factor of
Safety attained for fixture is 4 and for abutment it is 5 for implant placed for Case-1 and Factor of Safety
attained for fixture is 5 and for abutment it is 8 for the implant placed for Case-2.
The important parameters like the selection of implant and the bone density (D2 type of bone) from the
NNT viewer by New Tom has provided the valid inputs to perform FEA Analysis. The maximum Von-
mises stress obtained from the Implant Genesis Aktiv model dental implants made of Ti6Al4V chosen for
both the cases did not surpass the yield strength and the results obtained are under Factor of Safety
which shows that the Implant Genesis Aktiv implants are perfectly survived under allowable stress.
II. METHODOLOGY
The method used in the work is shown in below 3.1. In this method Three Dimensional patient digital
data is obtained from CBCT Scan and mostly all CBCT Scans generates the output in DICOM format.
Medical Modelling software named InVesalius is used for the segmentation of DICOM images. After
segmentation the DICOM file is converted to ‘STL’ file. STL error rectification is done by using Netfabb
software. The error free STL file is fed into the 3D printer for printing of the mandible. The following is a
step-by-step process from acquiring digital data to the production of the final dental model. In this work,
two persons aged 53 and 26 years, who had the first molar missing teeth on the mandible, were selected
for this work.
In this work virtual reconstruction of the structures in the human body is generated by using InVesalius
medical modeling software. The 2D images obtained using CT or MRI Scan software, a virtual 3D model
related to anatomical part which belongs to the human body is generated, later 3D DICOM images are
constructed and the software generates STL files (stereolithography). These files can be used on any AM
Machine to print physical 3D prototypes. The bio model preparation for Case 1 having 53 years of age is
shown below.
3D digital image is obtained with a CBCT scanner. Simulation of the internal structure present in the
human body is performed by using these imaging techniques. Inorder to maintain the data accurate, so
the helical scanning technology is used for complete volume scanning. This allows in creating numerous
sectors, and mainly, pixel size in every sector will reduce accordingly. The entire data related to the teeth
is obtained by using CBCT Scanner. A 3D information set is obtained and 270 sagittal slices with a slice
thickness of 0.2-0.5 mm is saved into DICOM file format. 3.2 shows the DICOM set obtained from the
CBCT scan.
CT scan data consists about the information pertaining to the ROI and the neighboring tissues. In this
regard useful scan data information needs to be obtained. Threshold image generation (gray matter) and
ROI selection is referred as segmentation, where the clear representation of ROI is shown. Below shows
the CT scan segmentation.
The threshold indicates about the segmented object (displayed with the color mask) which contains the
pixel information and its value usually represented in scale. In this case, the thresholds are made in
different scale, as shown in the , the threshold bar has a predefined scale ranging from minimum value of
226 to a maximum value of 3071. Based on the predefined scale the mandible is modelled. In various
proportions threshold is introduced. After thresholding is done the bones and teeth are divided into
masks. Below 3.5 shows the CT scan threshold.
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After thresholding particular region, a 2Dlayer to a 3D image is obtained. The fourth plane shown in
bottom right side represents a 3D view of the area chosen from threshold portion, as shown in the below
3.6.
The exported 3D Surface data file is saved in STL file format. STL is the standard file format which is
accepted by all AM Machines. Below 3.7 shows the data export into STL file format
The STL file correction is done by using Autodesk mesh mixer which ensures to prepare the files for 3D
Printing. The mandible which is imported using Autodesk meshmixer is shown in the 3.8 below. Maxilla
tooth portion is completely removed by choosing a planar cutting command.
Auto inspection is performed to eliminate the small errors and fine unwanted portions and ensure that
the model is free of errors and the smoothness of the STL model is attained (select>deform>smooth). 3.9
and 3.10 shows the auto inspection and smooth inspection done in Autodek Meshmixer software.
Before going to the final printing evaluation of the model and maintaining quality is necessary. The
Netfabb software automatically repairs the errors present in STL file and ensures the smooth printing
without any interruption.
Standard analysis provides information about the position, size, volume and area of selected parts and the
number of points, triangles, edges and shells. In the analysis of the wall thickness, it is possible to check
whether the part’s wall meets the requirements of the machine. The minimum value of critical wall
thickness is generated and all results below this number will be colored in red and the highest numbers
will be colored in green (until green is preferred). The final step of the mandibular file is prepared and
ready for 3D printing. s 3.12 and 3.13 show the standard analysis and the wall thickness performed in the
Netfabb software. Standard analysis provides information about the position, size, volume and area of
selected parts and the number of points, triangles, edges and shells. Wall thickness option is generally
used to check whether the part’s wall has reached the machine requirements or not. Minimum Wall
thickness value is generated and the values which are the lower the minimum wall thickness number is
colored as red and the values which are higher is colored as green (till the achievement of green color is
prefered). The final step of the mandible file is prepared and ready for 3D Printing. s 3.24 and 3.25 shows
the standard analysis and wall thickness performed in Netfabb software.
Identification of two cases having missing teeth in the first molar region of the mandible in different age
groups. According to the literature survey, the bite force is mainly generated in the molars, so the persons
who is having tooth loss in first molar region is chosen to carry the work.
 Acquiring the digital data of human jaw in DICOM (Digital Medical Imaging and Communication)
format and process the data in medical modeling software to convert DICOM to STL format (standard
triangulation language), then eliminate noise ratios and STL errors Using STL error correction
software, this is a key factor before entering the AM process. STL is a universal file format suitable for
all additive manufacturing processes.
 Additive Manufacturing of the mandible bio-models that are chosen.
 Model the dental implants based on the anatomy of the selected biological models.
 Determine the static torque and occlusal force of the dental implant placed in the first molar missing
area.
 Determination of the factor of safety of the dental implants selected for the two patients.
III. MODELLING
All the main points of the research work are written in this section. Ensure that abstract and conclusion
should not same. Graph and tables should not use in conclusion.
Within the scope the above mentioned objectives have been tried to accomplish. The persons aged 53
years and 26 years, the digital data was obtained from the CBCT scan (cone beam in the form of DICOM
format. In both cases, DICOM file data (medical digital communications) is transferred to the medical
modeling software known as InVesalius. InVesalius is a medical software used to create virtual

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reconstructions of human structures. Based on 2D images obtained from CT or MRI scanning devices, the
software can generate virtual 3D models corresponding to human anatomy. After creating a 3D DICOM
image, the software creates stereolithography (STL) files. These files can be used for rapid prototyping.
Rectification of STL errors is done by using Netfabb Software. When a 3D model is created, an error may
occur that prevents proper printing. Printing errors will occur mostly from the reverse lines, holes in the
grid, intersecting walls and unconnected edges. Netfabb software ensures smooth printing of the part.
The Makerbot desktop software is used to check 3D printing parameters, such as part orientation,
support structures, build process time and infill density, to ensure that parts 3D Printed correctly. The
Makerbot Replicator Z 18 3D printer with FDM (Fused Deposition Modeling) technique was used to 3D
print the bio models. For improving the success rates in the surgeries the dentist needs real time bio-
models. Using these physical bio-models, especially when placing implants, will improve the effective
communication for both surgeon and the patient.
The mandible STL files of the first molar missing cases are processed InVesalius's medical modeling
software and then corrected in Netfabb for finite element analysis. The error free STL files obtained from
Autodesk Netfabb software is processed in Meshmixer and Altair Hypermesh software to subsequently
perform geometric error correction and give the density of cortical bone and spongy bone inside the
mandible, and then converted to STEP (standard model for product exchange) Data) file format for
performing analysis by using ANSYS software. Both cases have D2 type bone densities. The Genesis Model
Aktiv implant has been selected for this work. Static analysis is carried out using finite element analysis.
In this work, CATIA V5 software was used to model Implant Genesis Aktiv Model dental implants with
different diameters and structures.
NNT Viewer software is used to identify implant location, bone density and implant depth to be inserted.
This software is widely used by dental surgeons in implantology and maxillofacial surgery to check CBCT
(cone Computed tomography) multiple views of the scans and planning of the surgeries. The Genesis
Aktiv Model implant made of grade 4 titanium (Ti-6Al-4V), is chosen to carry FEA analysis to evaluate the
insertion torque and occlusal force.
According to the literature, the basic stability of the implant mainly depends on the insertion torque, so
the insertion torques of 300 N mm, 350 N mm and 400 N mm are chosen according to the literature and
from the Genesis implant standards. The FEM is set to optimal osseointegration where the cortical and
cancellous bones are perfectly bonded to the implant. The first molar loads of 24N was used for
occlusion, and 50N is chosen for biting and 76N for maximum biting as reported for male persons in the
literature and the same is chosen to carry FEA analysis. In addition, as reported in the literature, based on
food hardness, the maximum bite force ranging from 20N to 120N is selected to perform maximum
Occlusal force. Von-Mises stress and total deformation is solved for, insertion torque occlusion force and
maximum occlusion force to identify the stress distributed on the implant and jaw bone within the
allowable range. For each product, the safety factor of safety plays an important role in evaluating
product failures. The Factor of Safety for the Implant Genesis Aktiv Models selected for the two patients
are calculated.
IV. RESULT
The authors can acknowledge professor, friend or family member who help in research work in this
section.
During the FDM process, the gantry system with the extruder head moves in the X and Y directions. The
table moves on the vertical Z axis. After placing the layer on the work table, the table goes down according
to the thickness of the layer, and subsequent layers are created in the same way.
FDM uses support materials as well as build materials to build complex parts and these support materials
helps in maintaining the structural integrity of the part. The support material can be easily breakable and
can be dissolved using dissolvable solvents.

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MakerBot Replicator Z18 starts printing objects by depositing several solid layers. These initial layers
which are deposited by the printer is termed as floor of the object and the depositing of the layers will
continue till the part gets printed. MakerBot Replicator Z18 starts each new layer of the object by printing
certain outlines of that layer. These are called shells. If there are multiple shells, the other shells will be
nested inside the first shell.
As shown in the below 4.3, either shells, floor or roof is filled with internal lattice structure known as
infill. Infill provides the internal support structure of the object. As the percentage of the infill increases it
will result in more threads of infill extrusion that are close together and if the infill percentage is low it
results in extrusion of fewer threads which are widely spaced. If the solid object is to be printed the infill
should be given as 100% and for hollow objects with no requirement of internal support structure the
infill density should be given as 0%.
There are several raw materials that can be used for FDM machines depending up on the machine
configuration. The raw material used in present work is PLA plastic (Polylactic Acid) supplied by
Makerbot industries.
The STL files of the mandibles which are processed in the Netfabb software earlier is taken and imported
into the Makerbot desktop software for pre-processing. Makerbot desktop software allows to change
different parameters of the machine which alters the various aspects of printing like quality, build time,
etc. The nozzle temperature required to build the part is 230° C. The orientation of the mandible bio-
models are set and the orientation ensures that maximum surface contact is maintained with the build
plate and the most possible symmetry is achieved to make it easy for the software for slicing purposes.
4.4 & 4.5 shows the print preview of the orientations and the support structure for case1 & 2.
The model is sliced virtually into number of layers depending on the parameters set in order for the
printer to print it. Once the slicing is done printing is started. The print statistics are documented in the
following Tables. Table 6.1 & 6.2 represents the print statistics for case 1 & case 2. s 4.6 & 4.7 shows the
3D Printed mandibles having first molar missing teeth for case 1 & case 2.
In the proposed system, we have implemented an organization-oriented system that would assist the
human resource department in short listing the right candidate for a specific profile. The system could be
used in many business sectors that will require expert candidates, thus reducing the workload of the
human resource department.
To perform surgery, dentists need real-time models to improve the effectiveness of surgery. Therefore,
the physical models are quite attractive and provide detailed patient anatomy from person to person with
good accuracy. Before performing complex surgeries, especially during implantation, the physical modes
are used to improve the communication between the doctor and the patient. Using InVesalius medical
modeling software the STL Rapid Prototyping files of the mandibles having first molar missing is
processed and the same is used for performing FEA Analysis of the dental implants by inserting them on
the first molar missing area.
V. CONCLUSION
STL rapid prototyping file attained from the InVesalius medical modelling software is processed in the
Autodesk Meshmixer for the rectification of errors in the file and the segmentation of the molar missing
area from the entire mandible is done. The STL file is imported in Altair Hypermesh (13.0) for further
geometry clean up where the solid STL is converted to surface form for rectification of errors in surfaces.
Then the bounding geometry is taken for the conversion of surfaces to solid followed by constructing and
giving the bone densities of the Cortical and Cancellous bones on the segmented file which are essential to
perform FEA Analysis. Export geometry is used to convert the file as STEP File to perform the FEA
Analysis. Hypermesh software is especially used to maintain the accuracy of the file.
The occlusal force is mainly generated in the molar part, so the person having first molar missing teeth is
selected for performing analysis. The thickness of the cortical bone for case-1 is taken as 1mm (D2 type of
bone) and 1.2mm (D2 type of bone) for case-2 as per the NNT Viewer shown in s 5.19 and 5.20. The
thickness of the cortical bone will vary from person to person and age to age. The segmented file is
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imported in CATIA V5 software to show the cross- sectional view of the cortical and cancellous bone
along with implant assembly and nerve model for case 1 and case-2 is shown.
To determine the insertion torque and Occlusal force static analysis is performed. Analysis of the implant
is carried out with the torque loads which are applied on the internal hex faces around the central axis of
the implant. On the base of the cortical bone the boundary conditions applied are all degrees of freedom.
Interfaces of bone, implant, abutment, cortical bone and cancellous bone are chosen as ‘Tie-Contact’
condition and implant system contact surfaces is chosen as sliding state with friction at the interface. The
implant insertion torque of 300 N-mm, 350 N-mm and 400 N-mm is considered based on the genesis
implants standards and as well as literature work done on Dental implant insertion torque and bone
density. As reported in the literature depending upon the hardness of the food, the average bite force is
ranging between 20N to120N. Similarly based on the literature work done on bite force measurement on
first molar area by using optical fiber bragg gratings method, the Occlusal force of 24 N is considered for
occlusion, 50 N is considered for biting and 76 N is considered for maximum biting to perform FEA
analysis . 5.23 and 5.24 shows the complete STL file of the mandible for case-1 representing location of
the first molar missing and the implantation to be done on the left side of the mandible and 5.25 and 5.26
represents the location of the first molar missing and implant position for case-2 on the right side.
Implant Genesis Aktiv Implants are made of Titanium grade 4, and possess ductile property, hence the
Factor of Safety is calculated along according to the ductile material property. Yield is measured at a point
of deformation in ductile materials. Hence for ductile materials FOS= Yield Strength / Maximum stress.
The factor of safety is calculated for implant fixture and abutment, since the fixture is made of Titanium
grade 4 and abutment is made of Titanium grade 5. Mechanical properties of titanium and its alloys used
in dental implantology are shown in table 6.4 as per the availability of content in literature. Tables 6.5 and
6.6 shows the Factor of safety results obtained for the Occlusal force of 24N, 50N and 76N for case-1 and
case-2 and table 6.7 shows the Factor of Safety results attained for maximum occlusal force of 120N for
case-1 and case-2.
As per the literature the insertion torque of 300 N-mm is necessary to achieve oseointegration for D-2
type of bone. Different torque loads of 300 N-mm, 350 N-mm and 400 N-mm are carried out as per the
torque standards of the Implant Genesis and also as per the literature to find the deformation and Von-
Mises stress occurring on the implant and the jaw bone. The maximum deformation obtained for
insertion torque of 400 N-mm for case-1 is 0.0065121mm and for case-2 it is 0.015658mm which is very
low and permissible to the jaw bone. The two selected cases are having D-2 type of bone with a slight
change in cortical bone thickness. For Case-1 von-mises stress obtained for the maximum insertion
torque of 400 N-mm is 86.83 Mpa and 104.92 for Case-2. As mentioned in the literature if the excessive
screwing force is performed along with the vertical force other than recommended torque loads will lead
to the destruction of implant threads and followed by the peri-implant bone loss. After performing
analysis results obtained shows that all the stresses which are formed on the jaw bone is permissible and
acceptable for the implant stability for the three torque loads selected for both the cases.
The total deformation maximum obtained for the occlusal force for maximum bite force of 76N is
0.024468mm for case-1 and 0.0097491mm for case-2 which is acceptable for the bone and the implant.
The von-mises stress is attained from the first molar occlusal force of 24N, 50N and 76N for Case-1 is
21.69 Mpa, 45.19 Mpa and 68.69 Mpa, and for Case-2 the von-mises stress attained for occlusal force of
24N, 50N and 76N is 18.89 Mpa, 39.35 Mpa and 59.81 Mpa. All the stress values obtained are permissible
to the mandibular bones for both cases.
VI. REFERENCES
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Process', FreieUniversität Berlin, and Humboldt-Universitätzu Berlin.

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International Research Journal of Modernization in Engineering Technology and Science

BIO- MODELLING AND ADDITIVE MANUFACTURING OF HUMAN

www.irjmets.com @International Research Journal of Modernization in Engineering, Technology and Science

www.irjmets.com @International Research Journal of Modernization in Engineering, Technology and Science

www.irjmets.com @International Research Journal of Modernization in Engineering, Technology and Science

www.irjmets.com @International Research Journal of Modernization in Engineering, Technology and Science

www.irjmets.com @International Research Journal of Modernization in Engineering, Technology and Science

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