Abstract
Additive manufacturing (AM) is an emerging fabrication method that has been frequently used to create personalized implants in the healthcare sector. Successful implementation of AM in the medical industry includes technological integration, interdisciplinary evaluation, and a reliable mechanism for accuracy assessment. While several detailed studies have been conducted in recent years to ensure the development of reliable implants, they mostly focus on traditional production methods, standard shapes, solid implants, and overlooked accuracy evaluation. These traditional implants are invariably dense, often ergonomically incompatible, and lack sufficient voids for new bone tissue regeneration in the implant. The advent of AM and its ability for customized mesh structures provide tremendous advantages, but also pose a profound conundrum for medical professionals responsible for evaluating and maintaining implant quality. Custom implants need to achieve a high degree of certainty that they fulfill aesthetic and precision requirements adequately. This study aims to design, fabricate, and evaluate a customized cranial implant that is accurate and aesthetically pleasing. Design, fabrication, and analysis are the three main phases of the methodology utilized to produce a realistic porous implant for cranial reconstruction. The design is acquired through mirror reconstruction in the medial modeling software, fabrication is accomplished using electron beam melting, and the fitting accuracy is achieved through expert assessment and coordinate measuring machine inspection. The structural analysis is also performed to investigate the dimensions of the pores and struts, as well as the structural consistency within the lattice specimen. The outcomes demonstrate that the cranial implant embedded with the dode thick structure exhibits adequate fitting accuracy, appropriate micro-hardness, sufficient compressive strength, and desirable cell attachment. In this investigation, the values of implant's fitting accuracy, hardness, compressive strength, and porosity are observed to be 0.9773 +/- 0.0437 mm, 343 HV, 67 MPa, and 75% respectively. Therefore, with the appropriate approach in cranial reconstruction, implant degradation can be minimized and aesthetic outcomes can be improved in skull surgical procedure for a healthier and better quality of life.