Biomechanical evaluation of an anatomical bone plate assembly for thin patella fracture fixation fabricated by titanium alloy 3D printing

This study established and evaluated the feasibility of a three-dimensional (3D)-printed titanium anatomical surface with adjustable thin bone plate assembly (AATBP) for patella fracture fixation. The AATBP was 1.6 mm in thickness and divided into a proximal plate (PP) with locking screw holes and a distal plate (DP) (0.4 mm in thickness) with compressive screw holes for assembly using a ratchet mechanism to adjust the total fixation height according to the patella size. Two pairs of hooks were designed on the proximal/distal edges to allow passage through the tendon to grip the fractured fragments. 3D printing combined with Computer Numerical Control (CNC) drilling was performed to manufacture the AATBP. Four-point bending and surface roughness tests were performed to evaluate the AATBP mechanical behavior. A cyclic (300 times) load test with 15-kg weights was adopted to compare the biomechanical stability between the AATBP and conventional tension band wiring (TBW) fixations. A parallel finite element (FE) analysis was achieved to understand the fracture gap and bone stress in the two different fixations on a transverse patella fracture. The result showed that the maximum AATBP manufacturing error was 3.75%. The average fracture gaps on the medial/lateral sides after cyclic loads were 2.38 ± 0.57 mm/2.30 ± 0.30 mm for TBW and 0.03 ± 0.01 mm/0.06 ± 0.03 mm for AATBP fixations. The same trend occurred in the FE simulation. This study confirmed that a complicated thin bone plate, including the anatomical surface, hooks, and ratchet with size-adjustable characteristics, can be fabricated using metal 3D printing with acceptable manufacturing error and reasonable anatomical surface/thin bone plate assembly fitness. Biomechanical cyclic tests and FE simulation showed that the AATBP fixation is superior to the conventional TBW for patella transverse fractures.