Abstract
Rehabilitation of the cranium’s bones is considered a complicated procedure that presents a challenge to the surgical staff. Typically, the primary focus when designing an implant should involve selecting optimal design techniques and materials. Material and design should provide a strong, comfortable, simple-to-fit, and attractive implant. Therefore, this study aims to design a suitable customized PEEK implant. Initially, 3D models of the damaged region were created using interactive CAD modelling techniques. While creating the implant model used mirror-based reconstruction. Furthermore, finite element analysis was implemented to evaluate the implant’s stability and structural strength. Then morphological analysis was used to assess the precision of virtual fitting. Finally, fused filament fabrication was used to manufacture it. Under simulation, the implant was subjected to a constant load of 50 Newtons and intracranial pressures. According to the simulation results, the maximum Von Mises stress was about 22.057E-2 MPa, the Von Mises strain was 5.8135E-5, and the deformation was 1.9103 µm. That means the maximum recorded stress is quite low in comparison with the material’s yield strength. This reflects the ability to endure and maintain safety of the studied implant. While the morphological test showed that the exterior profile curvature contours were uniformly reconstructed, maintaining contiguity between the implant and the skull model, which indicates a suitable fit.