Bone response to implant surface morphology

This study was designed to measure implant osseointegration using different surface treatments. Bilateral distal intramedullary implantation of titanium cylinders 25 mm x 5 mm was performed in 60 rabbits. The 3 surfaces tested were fiber mesh, mean pore size 400 microns; grit-blasted, mean surface roughness 6 microns; and acid-etched, mean surface roughness 18 microns. Scanning electron microscopy was used to measure the percentage of the surface of each implant in contact with bone at 2, 6, and 12 weeks postimplantation. Mechanical pull-out testing of the bone-implant interface was performed at 12 weeks. Overall, acid-etched surfaces demonstrated greater mean osseointegration than fiber mesh surfaces. All 3 surfaces demonstrated similar interface strengths. Acid etching has potential as a means of enhancing bony apposition in cementless fixation.     

Microgrooved subcutaneous implants in the goat

We investigated the behavior of microgrooved implants in soft tissue using polystyrene implantable disks, either smooth or microgrooved (1-10 microm) on both sides. The implants were placed subcutaneously in a goat for 1, 4, or 12 weeks. Light and transmission electron microscopy showed that fibrous capsule formation around the implants was fairly uniform. After 1 week the implants were covered with a fibrous capsule about 80 microm thick. The collagen matrix was loose, and many inflammatory cells were present. After 4 weeks the matrix was more dense and contained many newly formed blood vessels. At the implant surface a layer of inflammatory cells about 10 microm thick had accumulated. Finally, after 12 weeks the matrix had densified. One cellular layer of inflammatory cells was present at the implant surface. We carried out histomorphometric measurements of capsule thickness, inflammatory layer thickness, and the number of blood vessels. Capsule thickness appeared not to decrease with time. Further, these measurements showed that there were no differences in tissue reaction between smooth and microgrooved implants. On the basis of our observations, we suggest that 1 microm deep and 1-10 microm wide microgrooves do not influence tissue response around polystyrene implants in soft tissue.     

Mechanical and histological evaluation of amorphous calcium phosphate and poorly crystallized hydroxyapatite coatings on titanium implants

The effect of amorphous calcium phosphate (Ca/P) and poorly crystallized (60% crystalline) hydroxyapatite (HA) coatings on bone fixation to "smooth" and "rough" (Ti-6A1-4V powder sprayed) titanium-6Al-4V (Ti) implants was investigated. Implants were evaluated histologically, mechanically, and by scanning electron microscopy (SEM) after 4 and 12 weeks of implantation in a rabbit transcortical femoral model. Histological evaluation of amorphous vs. poorly crystallized HA coatings showed significant differences in bone apposition (for rough-coated implants only) and coating resorption (for smooth- and rough-coated implants) that were increased within cortical compared to cancellous bone. The poorly crystallized HA coatings showed most degradation and least bone apposition. Mechanical evaluation, however, showed no significant differences in push-out shear strengths between the two types of coatings evaluated. Differences between 4 and 12 weeks were significant for coating resorption and push-out shear strength but not for bone apposition. Significant enhancement in interfacial shear strengths for bioceramic coated as compared to uncoated implants were seen for smooth-surfaced implants (3.5-5 times greater) but not for rough-surfaced implants at 4 and 12 weeks. Rough implants showed greater mean interfacial strengths than uncoated smooth implants at 4 and 12 weeks (seven times greater) and to coated smooth implants at 12 weeks only (two times greater). Mechanical failure of the bone/coating/implant interface consistently occurred within the bone, even in the case of the poorly crystallized HA coatings, which had almost completely resorbed on rough implants. These results suggest that once early osteointegration is achieved biodegradation of a bioactive coating should not be detrimental to the bone/coating/implant fixation.     

Rapid bone resorption adjacent to hydroxyapatite-coated implants

This paper describes rapid bone resorption in the peri-implantitis of HA implants based on both our clinical observations of and histological research on extracted dense hydroxyapatite (HA) implants. The surfaces of extracted HA implants were rough, although they were smooth at fixture placement. Plaque formed on the necks of the implants, whereas little plaque was seen on the bottoms. The plaque consisted of cocci and rods, including filamentous bacteria. Few spirochetes were observed. Although surrounding bone was formed rapidly around the HA implant, bone thickness gradually decreased compared with the titanium implant. These facts suggest that the rigid biointegration of HA with the thin surrounding bone--that is, the overstressing of the bone--causes rapid bone resorption rather than plaque accumulation on HA.     

Histological and biomechanical analysis of bone and interface reactions around hydroxyapatite-coated intramedullary implants of different stiffness: a pilot study on the goat

We hypothesized that reduced stem stiffness of orthopaedic implants contributes to a high risk of loosening, since interface stresses and relative motions may exceed a tolerable range. To study this hypothesis, three types of load-bearing implant with different stiffnesses were inserted into the tibia of the goat. Histological analysis was performed of bone repair after insertion of the implant, bone ingrowth, interface disruption and loosening. A finite element model of the configuration provided the quantitative range of interface stresses and relative motions for the present experiment. The implants were made out of stainless steel, hollow titanium and a thin titanium core covered with a polyacetal coating. The stiffness ratios of these implants were approximately 10:4:1, respectively. All implants were coated with a layer of hydroxyapatite (HA) in order to minimize the possible biological effects of the different implant materials. Irrespective of the type of implant, there was a repair phase that lasted 6-12 weeks. The stiff implants functioned well. Large areas of bone bonding to the HA layer were found after the repair phase at 12 weeks postoperatively. After 24 weeks, some signs of loosening were observed. More loosening occurred with the hollow titanium and polyacetal implants, mainly during the repair phase. Three hollow titanium and three polyacetal coated implants survived this period, and were killed after 24 weeks. The integrity of the HA layer at the bone-implant interface of the titanium implants was good. In the polyacetal implants, the repair reaction of the cortical bone was incomplete. Bone ingrowth into HA was largely lacking. In conclusion, we found significant differences in the repair and interface reactions around implants of different stiffness. Stiff implants showed favourable initial interface conditions for bone ingrowth. Intermediate and flexible implants provoked unfavourable interface conditions for initial bone ingrowth. The finite element study showed that the flexible stems produce larger micromotions and higher interface stresses at the bone-prosthesis interface than the stiff stems, indicating an explanation for the histological findings.     

Quantitative histologic evaluation of LTI carbon, carbon-coated aluminum oxide and uncoated aluminum oxide dental implants

The response of mandibular bone to identical geometry LTI carbon, carbon-coated aluminum oxide, and uncoated aluminum oxide blade-type dental implants in baboons for 2 years was evaluated using histologic, microradiographic, and scanning electron microscopic methods. In addition, a quantitative histologic analysis was performed identifying the type, amount, and distribution of tissue surrounding the dental implant systems. This is the final phase of a study investigating the effect of implant elastic modulus and implant surface chemical composition on the performance of dental implants. Previous studies have utilized clinical and radiographic evaluations, postretrieval mechanical testing, and finite element stress analysis to evaluate the dental implant performance. The results of the histologic study revealed a direct implant-bone interface with no intervening soft tissue in 16 of the 21 implants (76%). A fibrous tissue interface was observed in 5 of 21 implants (24%). Quantitative histologic results for the implants with a direct implant-bone interface showed statistically larger crestal cortical plates (p less than 0.05) and greater area fraction crestal cancellous bone (p less than 0.05) in the LTI carbon implant compared to the carbon-coated and uncoated aluminum oxide implants. The carbon-coated and uncoated aluminum oxide implants demonstrated statistically greater area fraction cancellous bone at the inferior region of the implant (p less than 0.05) and thinned and reduced crestal cortical plates when compared to the LTI carbon implants. The results indicate that significant stress shielding of the crestal bone had occurred with the rigid carbon-coated and uncoated aluminum oxide implants when compared to the LTI carbon implants which had a material elastic modulus similar to cortical bone. Based upon the histologic results, it appears that the LTI carbon implants with the direct implant-bone interface exhibited a greater potential for long-term successful performance compared to the aluminum oxide substrate implants.     

Bone ingrowth to implant surfaces in an inflammatory arthritis model

Many studies have shown enhanced bone apposition to implants coated with hydroxyapatite, but the optimum implant texture, especially in abnormal trabecular bone, is unclear. The purpose of this project was to evaluate the histological and mechanical properties of cylindrical implants with three different surface textures that were placed in the cancellous bone of the distal femur of the rabbit after the production of an inflammatory knee arthritis. The three implant surfaces included a beaded surface (Group A), a beaded surface coated with hydroxyapatite (Group B), and a smooth surface coated with hydroxyapatite (Group C). The right knees of 36 rabbits were injected with carrageenan twice a week for 2 weeks. Then bilateral implantations were performed, with 12 rabbits in each group receiving identical implants in the right and left knees. The rabbits were killed 6 weeks after surgery. Mechanical (push-out test) and histomorphometric analyses were performed to determine the quality and quantity of bone ingrowth. In Group A, there was virtually no direct contact (a 20-60-microm clearance) between the bone and the beaded surfaces. Direct contact between the bone and the implant surfaces was seen in Groups B and C. The thickness and number of trabeculae were smaller on the arthritic side than on the control side for all groups but were not different between groups for either the control or the arthritic side. Mechanical testing showed that the shear strength of the interface was weaker on the arthritic side in all groups. The results suggest that inflammatory arthritis induced by carrageenan may influence the quality of local bone (osteopenic changes) and hence compromise the bone apposition and mechanical stability of the interface between the implant and bone.     

Lesions in the dentate hilum and CA2/CA3 regions of the rat hippocampus produce cognitive deficits that correlate with site-specific glial activation

The aim of the present experimental investigation was to study the morphological and dimensional changes of bone, augmented at titanium implants by a membrane technique, taking place after membrane removal. In 12 rabbits, screw-shaped titanium implants were inserted in the tibial metaphyses in such a way that 5 threads became uncovered with bone. Surgery was performed on 2 occasions in order to retrieve specimens with different follow-up times. An e-PTFE barrier and a titanium device were used to provide space for bone formation. In 1 tibia of each rabbit, the membranes and spacers were removed after 8 weeks of healing, and the implants followed for 16 more weeks. Impressions were taken at day 0 and after 8 and 24 weeks of healing and plaster models were produced. In the contralateral tibiae, implants were inserted either 16 or 8 weeks prior to sacrifice. Measurements were made on the plaster models in 3 dimensions at 35 points around each implant in a coordinate measuring machine. Specimens taken 8, 16 and 24 weeks after insertion were analysed by means of light microscopical morphometry. The coordinate measurements showed that, in mean, 1.92 mm of bone had been formed during the first 8 weeks. A statistically significant loss of the height of the newly formed bone (0.70 mm) and thereby reduction of bone volume was found 24 weeks postoperatively. The volume decrease of the newly formed bone was more pronounced beside the implants than over the implant body. The histology showed that woven bone had been formed at the implants after 8 weeks. Further bone formation and remodelling and a net increase of mineralized bone were seen. The degree of bone-implant contact and bone area in the threads increased with time. The present study showed that coordinate measurements on plaster models, obtained from the experimental areas, in combination with histology, form a useful technique to study long-term changes of augmented bone. It was found that bone formed by a barrier membrane technique, decreased in volume during a 16-week follow-up period after barrier removal. Less dimensional changes were observed for the bone formed over the implant body, indicating that a solid surface may have a stabilizing effect on the augmented bone.     

Dry-process surface modification for titanium dental implants

Because dental implants contact many different tissues, the implant material must have optimum surface compatibility with the host bone tissue, subepithelial connective tissue, and epithelial tissue. In addition, dental implant surfaces exposed to the oral cavity must remain plaque-free. Such materials can be created under well-controlled conditions by modifying the surfaces of metals that contact those tissues. “Tissue-compatible implants,” which are compatible with all host tissues, must integrate with bone tissue, easily form hemidesmosomes, and prevent bacterial adhesion. This research was aimed at developing such tissue-compatible implants by modifying titanium surfaces using a dry process for closely adhering to the titanium substrate and ensuring good wear resistance. The process includes ion beam dynamic mixing (thin calcium phosphates), ion implantation (Ca⁺, N⁺, F⁺), titania spraying, ion plating (TiN, alumina), and ion beam mixing (Ag, Sn, Zn, Pt) with Ar⁺. At the bone tissue/implant interface, a thin calcium phosphate coating and rapid heating with infrared radiation were effective in controlling the dissolution without cracking the coating. This thin calcium phosphate coating may directly promote osteogenisis, but it may also enable immobilization of functional proteins or drugs. At the oral fluid/implant interface, an alumina coating and F⁺ implantation were responsible for inhibiting the adhesion of microbial plaque. In conclusion, dry-process surface modification is useful in controlling the physicochemical nature of surfaces, including the surface energy and the surface electrical charge, and in developing tissue-compatible implants.     

The activation of eNOS by copper ion (Cu2+) in human pulmonary arterial endothelial cells (HPAEC)

This study examined the influence of diabetes mellitus on bone formation around cylindrical titanium (Ti) implants (1.0 mm in diameter and 1.5 mm in length) inserted transcortically and extending into the medullary canal of rat tibiae using light and fluorescence microscopies and image processing. Forty-eight male Wistar King A rats (age 5 weeks) were used in this experiment. Streptozotocin was injected intraperitoneally to induce diabetes and the serum glucose concentration was checked to ensure the induction of diabetes prior to implant placement and at the time of sacrifice. The animals were sacrificed 7, 28, 56, or 84 days after placement. Toluidine blue-stained undecalcified sections were prepared for histological observation and image analysis. The Ti implants in the control group became increasingly encapsulated with a bone layer. The implants in the diabetes-induced (DI) group were also surrounded with a thin bone layer. Abundant adipocytes were observed in the DI group as compared with the control group. Quantitative evaluation indicated that the control group showed a significantly higher percent of bone contact, and thickness of surrounding bone and area than the DI group. Consequently, the present study suggests that uncontrolled diabetes would hinder bone formation around Ti implants in rats.     

Effects of multiple sterilization on surface characteristics and in vitro biologic responses to titanium

PURPOSE: This study evaluates the surface changes and effects on in vitro cell attachment and spreading brought about on prepared commercially pure titanium by multiple exposures to common sterilization methods. MATERIALS AND METHODS: Discs of commercially pure titanium were prepared to approximate the surface roughness of commercially available bone miniplates. Samples underwent sterilization by exposure to ultraviolet light; ethylene oxide sterilization (1, 5, or 10 cycles); or by steam autoclaving (1, 5, or 10 cycles). Representative surfaces from these sterilization groups were examined using a series of surface analytical techniques including scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), auger electron spectroscopy (AES), and contact angle measurements. Cell attachment assays using murine fibroblasts were then performed on titanium surfaces from each sterilization group and on tissue culture plastic controls. Sterilized surfaces contained O, C, and N contaminants, which affected surface energetics. Mean percent cell attachment values for each group were obtained for periods of up to 1 hour. Representative samples from each group were examined using SEM to ascertain cell spreading and morphology for each sterilization group. RESULTS: Ultraviolet (UV) sterilized surfaces showed no changes from the unsterilized state macroscopically or under SEM. UV surfaces showed cell attachment levels similar to control surfaces at all intervals, and a chronologic progression of cell spreading. Ethylene oxide-sterilized surfaces showed occasional bluish discoloration and a microscopic particulate contaminant, resulting in modest decreases in cell attachment levels without strong correlation to numbers of sterilization cycles. Autoclaved surfaces generally showed the greatest discoloration and heaviest particulate contamination. Cell attachment levels were lower, and cell spreading was diminished compared with the ethylene-oxide-treated group. CONCLUSIONS: Both ethylene oxide and steam autoclave sterilization contaminated and altered the titanium surface, resulting in decreased levels of cell attachment and spreading in vitro. Although corroborative in vivo experiments should be conducted, the results of this study indicate that some multiple sterilization regimens for metallic materials may pose serious biologic concerns.     

Influence of metal implants on infection. An experimental study in rabbits

We implanted cylinders of cobalt-chrome or titanium, with smooth or porous surfaces, into rabbit bones which had been inoculated with suspensions of Staphylococcus aureus in various doses. The bacterial concentration required to produce infection of porous-coated titanium implants was 2.5 times smaller than that necessary to infect implants with polished surfaces. Porous-coated cobalt-chromium implants required bacterial concentrations that were 40 times smaller than those needed to infect implants with polished surfaces, and 15 times smaller than those required to infect porous-coated titanium implants. The other advantages and disadvantages of the various implants, such as improved osseointegration, larger ion-release surfaces, surface wear and relative stiffness, must be weighed against the higher infection rates in the porous-coated implants, and particularly in the cobalt-chromium implants.     

A histological study on tissue responses to titanium implantation in rat maxilla: the process of epithelial regeneration and bone reaction

The present study aimed to establish a titanium implantation model using rat maxillae as well as demonstrate the chronological tissue responses to implantation. Pure titanium implants were inserted in the upper first molar extraction sites of Wistar rats 1 month after tooth extraction. The animals were sacrificed at 1 to 30 days postimplantation, and prepared tissue specimens were processed for light microscopy. The removal of implants from tissue blocks was done using 2 methods: mechanical removal or a cryofracture technique. In the early stages, peri-implant tissues showed severe damage to the oral epithelium and collagen bundles with significant inflammatory cell infiltration. The peri-implant epithelium grew apically along the implant by 10 days postimplantation, and regenerated to show a similar feature of junctional epithelium seen in normal rats at 15 days postimplantation, at which time no signs of inflammation were observed. The regenerated collagen bundles in the connective tissue were arranged circumferentially to the implants in the horizontal sections. New bone formation first appeared around the implants at 5 days postimplantation, covering the entire perimeter of implants by 30 days postimplantation. Scanning electron microscopic observations of the surface texture of the removed implants suggest the probability of an adhesive mechanism between the implants and the peri-implant epithelium and/or the alveolar bone. These findings indicate that this experimental model is useful for detailed analysis of peri-implant tissue because of its easy implantation procedure.     

Inhibition of eFGF expression in Xenopus embryos by antisense mRNA

This pilot study analyzed the bone reactions to early loaded titanium plasma-sprayed implants. A total of 24 titanium plasma-sprayed implants (12 in the maxilla and 12 in the mandible) (Primary Healing Implant, Legnano) were inserted into four Macaca fascicularis monkeys with instruments specially designed to obtain a precise fit of the implant in the bone socket. A metal superstructure was cemented into 10 mandibular and 10 maxillary implants 15 days after implant insertion. The four remaining implants were used as controls. Eight months after implant placement, a block section was carried out, the defect was filled with nonresorbable hydroxyapatite, and all 24 implants were retrieved. The implants were treated to obtain thin ground sections that were examined under normal and polarized light. Histologic analysis showed that bone was observed around the implant surface in all implants. Morphometric analysis demonstrated that bone lined 67.2% (SD = 3.1%) of the maxillary implant surface, and 80.71% (SD = 4.6%) of the mandibular implant surface. No differences were found in the percentage of bone-implant contact in the control implants. In the loaded implants, however, the bone around the implants had a more compact appearance. The study demonstrated that it is possible to obtain a high percentage of bone-implant contact in early loaded titanium plasma-sprayed implants.     

Confirmation of a prognostic index for patients with inoperable non-small cell lung cancer

The surfaces of hydroxyapatite-glass-titanium (HA-G-Ti) functionally gradient composite and titanium bars were treated with electrochemical apatite deposition, and a cathodic current was applied at 62 degrees C in a solution containing calcium and phosphate ions. Specimens with and without the electrochemical surface treatment were implanted in the femurs of Japanese white rabbits. The rabbits were sacrificed at 3, 6, and 9 weeks after implantation, and the bonding strengths of bone to these specimens were determined by a pull-out method. At 3 and 6 weeks after implantation the specimens with the electrochemical surface treatment showed larger values for the Weibull modulus and characteristic strengths than those of untreated specimens, whereas there was no remarkable difference in the results at 9 weeks. Especially the pull-out strengths of surface-treated specimens were significantly larger than the untreated ones at 3 weeks after implantation. Scanning electron microscopy and Fourier transform infrared absorption spectroscopy of the specimen surface after implantation demonstrated that formation of new bone was enhanced by the electrochemical surface treatment. It can be concluded that the electrochemical surface treatment undoubtedly contributes to the early stage fixation between bone and implant.     

The use of grommets for flexible hinge toe implants. A case report

The postmortem examination of bilateral first metatarsophalangeal flexible hinge toe implants in a 66-year-old woman with rheumatoid arthritis is reported. The prosthesis had been inserted with grommets in 1 joint and without grommets in the other 2.5 years before her death. The implants were removed, and the bone/implant interfaces were examined microscopically by hematoxylin eosin stains and an electron probe microanalyzer. Surfaces of the implants were examined by scanning electron microscopy. Silicone particles within the fibrous tissue at the bone/implant interface, and a tear and significant scuffing of the implant surface, were detected in the joint without grommets. Such changes were not detected in the joint with grommets. These findings suggest that grommets may improve implant durability and preventing silicone synovitis.     

Microscopical features in retrieved human Branemark implants: a report of 19 cases

The authors present a histologic analysis of 19 Branemark titanium implants retrieved for different causes: four implants were removed for abutment fracture, one for dental nerve dysesthesia, two for bone overheating, two for peri-implantitis, nine for mobility, one for unknown causes. In the implants removed for fracture a high bone-implant contact percentage was present (71.83 +/- 4.96%) with compact, mature bone at the interface. The picture of the failure due to bone overheating was characteristic with the presence of bone sequestra and of a gap between implant and bone filled by lymphocytes and plasma cells: many bacteria surrounded the necrotic bone and no newly regenerated bone was present. In peri-implantitis an inflammatory infiltrate was observed in the peri-implant tissues: a dense fibrous connective tissue was present around implants failed for mobility. The microscopical picture is certainly extremely important in identifying the causal determinants of an implant failure.     

Maxillary sinus augmentation using different grafting materials and dental implants in monkeys. Part I. Evaluation of anorganic bovine-derived bone matrix

The aim of this study was to evaluate clinically, histologically and histometrically the use of anorganic bovine bone matrix (i.e. Bio-oss) as a grafting material for maxillary sinus augmentation procedures. In 4 adult male rhesus monkeys (i.e. Macaca mulatta) the 1st, 2nd and 3rd maxillary molars on one side of the jaws were extracted. The remaining bone between the alveolar crest and the bottom of the sinus was then reduced to 3-4 mm. After 3 months, maxillary sinus augmentation procedures were performed on one side of the jaws in each monkey and the sinuses were grafted with the bovine bone matrix. At that time, 2 IMZ pure titanium plasma coated implants were immediately placed into the augmented sinuses (i.e. simultaneous implants-loaded group). After 4 months, 2 additional similar implants were placed into these previously augmented sinuses (i.e. delayed implants-loaded group). Four months later, the abutment connection was performed and all 4 implants were loaded with a gold-alloy bridge for 6 months (i.e. until sacrifice of the animals). The contralateral side of each monkey received the same treatment with the exception that the extractions were performed 7 months after those in the opposite side and that the implants in this side were not loaded. Thus, 2 additional study groups (i.e. simultaneous implants-unloaded group and delayed implants-unloaded group) were obtained. Clinically, all loaded implants were stable at the day of sacrifice. Histologically, the grafted sinuses exhibited significant bone formation with integration of the bovine bone matrix particles to the new bone. Direct mineralized bone-to-implant contact was greater for the delayed implant placement groups than for the implants installed simultaneously with the sinus augmentation. Furthermore, the percentage of direct mineralized bone-to-implant contact was greater in the residual bone than in the augmented area. It was concluded that the anorganic bovine bone matrix facilitated bone formation and implant osseointegration in the augmented sinuses and that the delayed implant placement in combination with the sinus augmentation procedure seemed to be preferable.     

Tissue regeneration in bony defects adjacent to immediately loaded titanium implants placed into extraction sockets: a study in dogs

In this study of six greyhound mandibles, 24 implants were placed into extraction sockets. Eighteen of the implants were connected with abutments and immediately placed into normal function, and the remaining six submerged implants served as controls. At placement, dehiscence areas were created adjacent to 12 of the implants to study bone regeneration in extended membrane-protected defects. Six of the defects were covered with expanded polytetrafluoroethylene membranes, and six of the defects were augmented with autologous bone grafts and covered with expanded polytetrafluoroethylene material. The clinical and radiographic evaluations demonstrated that all implants achieved functional osseointegration and no implants were lost. Implant sites where membranes were used to regenerate bone over dehiscence defects demonstrated a high rate of membrane exposure and variable response to treatment. On completion of the study at 16 weeks, histomorphometric analysis demonstrated osseointegration with direct bone-to-implant contact for all implants, although the percentage of contact varied considerably. Histomorphometry indicates that the quality of osseointegration may be less favorable than the clinical and radiographic result would suggest.     

CAD/CAM (computer-aided design/computer-aided manufacturing) titanium implants for cranial and craniofacial defect reconstruction

The reconstruction of craniofacial bone defects with intraoperatively modeled prosthesis restricts the choice of material and its biocompatibility and the prediction of the esthetic result. A prolonged duration of the surgical procedure and an increased stress on the patient are consequences. In contrast, modern industrial CAD/CAM-systems allow the prefabrication of titanium prosthesis: An individual computer-based 3D model of the bony defect is generated after acquisition, transfer and evaluation of helical CT data. Basing on these data the individual prosthesis-shape is designed using freeform surfaces geometries and fabricated by a numerically controlled milling machine. The conical margins of this prosthesis-geometry are generated by the borders of the defect with a minimal gap of 0.25 mm, and the surface contours by considering the non-affected neighbouring contours with a constant thickness of 1.5 mm. Individual osteosynthesis-microplates for fixation are integrated in design and manufacturing if screw-holes cannot be integrated in the thin margins of the implants. The radiological and clinical results of 17 patients after reconstruction of craniofacial bone defects with CAD/CAM titanium implants were good. Complications were not observed.