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<p>Orthopedic bone plates necessitate high mechanical strength, accurate dimension compliance, and adaptability to patient-specific geometries. Traditional metallic implants offer superior mechanical performance, yet are expensive to manufacture, waste material in production and have limitations in their flexibility for design geometry modification. Additive manufacturing, especially fused deposition modeling (FDM), could provide an alternative for the fabrication of complex biomedical geometries with thermoplastic materials; however, mechanical performance and dimensional accuracy of FDM-fabricated bone plates are still very much dependent on optimization of process parameters. In this work, a systematic Taguchi-based optimization of the key Fused Deposition Model (FDM) parameters for the fabrication of an orthopedic 4.5&#xa0;mm reverse-engineered T-plate prototype is reported. Eighteen experimental runs were solidified at different build orientation, infill pattern, layer height, and line width to evaluate manufacturing time, dimensional accuracy and bending stiffness. The outcomes show that infill pattern and build orientation have a significant impact on bending stiffness while layer height and line width influence geometric fidelity and throughput. The best combination of parameters was Y-oriented deposition, 0.10&#xa0;mm layer height, 0.50&#xa0;mm line width, concentric infill as it delivered the best structural stiffness-to-dimensional precision ratio. While the PLA prototype features a stiffness, which is not in line with any clinical load bearing requirements, the established trends in stiffness provide a statistically validated basis for optimization within orthopedic plate prototyping. The framework proposed here opens a pathway allowing the new approach to be transferred toward high-performance biomedical polymers or metallic additive manufacturing systems in future translation work.</p> Graphical abstract <p>Schematic overview of optimizing Fused Deposition Modelling parameters for customized 4.5 mm orthopedic T-plates. The study compares FDM additive manufacturing to traditional metal implants, using a Taguchi orthogonal array to assess build orientation, infill pattern, layer height, and line width. Optimal settings balance higher bending stiffness, improved dimensional accuracy, and lower stress shielding risk for patient-specific implants.</p> <p></p>

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Preliminary prototyping and parameter optimization of FDM-based custom bone plates: a feasibility study for orthopedic fixation

  • 期刊论文

  • 发表日期：

    2026年5月20日

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  • Rochmad Winarso,
  • Taufiq Hidayat,
  • Budi Gunawan,
  • Fajar Nugraha,
  • Sri Mulyani

摘要

Orthopedic bone plates necessitate high mechanical strength, accurate dimension compliance, and adaptability to patient-specific geometries. Traditional metallic implants offer superior mechanical performance, yet are expensive to manufacture, waste material in production and have limitations in their flexibility for design geometry modification. Additive manufacturing, especially fused deposition modeling (FDM), could provide an alternative for the fabrication of complex biomedical geometries with thermoplastic materials; however, mechanical performance and dimensional accuracy of FDM-fabricated bone plates are still very much dependent on optimization of process parameters. In this work, a systematic Taguchi-based optimization of the key Fused Deposition Model (FDM) parameters for the fabrication of an orthopedic 4.5 mm reverse-engineered T-plate prototype is reported. Eighteen experimental runs were solidified at different build orientation, infill pattern, layer height, and line width to evaluate manufacturing time, dimensional accuracy and bending stiffness. The outcomes show that infill pattern and build orientation have a significant impact on bending stiffness while layer height and line width influence geometric fidelity and throughput. The best combination of parameters was Y-oriented deposition, 0.10 mm layer height, 0.50 mm line width, concentric infill as it delivered the best structural stiffness-to-dimensional precision ratio. While the PLA prototype features a stiffness, which is not in line with any clinical load bearing requirements, the established trends in stiffness provide a statistically validated basis for optimization within orthopedic plate prototyping. The framework proposed here opens a pathway allowing the new approach to be transferred toward high-performance biomedical polymers or metallic additive manufacturing systems in future translation work.

Graphical abstract

Schematic overview of optimizing Fused Deposition Modelling parameters for customized 4.5 mm orthopedic T-plates. The study compares FDM additive manufacturing to traditional metal implants, using a Taguchi orthogonal array to assess build orientation, infill pattern, layer height, and line width. Optimal settings balance higher bending stiffness, improved dimensional accuracy, and lower stress shielding risk for patient-specific implants.