Comparison of the biomechanical behavior between commercial and 3D-printed patient-specific Ti6Al4V L-Shaped titanium plates following le fort i osteotomy using finite element analysis: A technical Note

•The study provided an advanced finite element analysis with a comprehensive comparison and visualization of mechanical stresses, strains, and displacements, enhancing pre-surgical planning and prediction of post-operative outcomes.•Both the commercial and 3D-printed Ti6Al4V titanium plates showed close stress, strain, and displacement values under varying occlusal forces, indicating a marginal difference in biomechanical behaviors.•The 3D-printed Ti6Al4V plates demonstrated slightly lower displacement and strain under equivalent forces, suggesting a potential advantage in maintaining structural integrity post-operation.•Maximum stress concentrations were observed at the vertical change in the left posterior area between maxillary segments, with the 3D-printed model exhibiting higher stress values, potentially impacting long-term stability.•Our study supports the use of 3D-printed personalized fixation plates for their proven postoperative accuracy and excellent anatomical fit. However, in terms of mechanical stability, there is no significant difference under the 125, 250, 500 N/mm2 occlusal forces. To evaluate and compare the biomechanical behavior of three-dimensionally (3D) printed patient-specific Ti6Al4V with commercially made titanium mini plates following Lefort-I osteotomy using finite element analysis. Le Fort I osteotomy was virtually simulated with a 5 mm maxillary advancement and mediolateral rotation in the coronal plane, resulting in a 3 mm gap on the left side's posterior. Two fixation methods were modeled using software to compare 3D-printed Ti6Al4V and commercial titanium mini plates, both featuring a 4-hole l-shape with thicknesses of 0.5 mm and 0.7 mm at the strategic piriform rim and zygomaticomaxillary buttress locations. Using ANSYS R19.2, finite element models were developed to assess the fixation plates and maxilla's stress, strain, and displacement responses under occlusal forces of 125, 250, and 500 N/mm². This comparative analysis revealed slight variation in stress, strain, and displacement between the two models under varying loading conditions. Stress analysis indicated maximum stress concentrations at the vertical change in the left posterior area between maxillary segments, with the Ti6Al4V model exhibiting slightly higher stress values (187 MPa, 375 MPa, and 750 MPa) compared to the commercial titanium model (175 MPa, 351 MPa, and 702 MPa). Strain analysis showed that the commercial titanium model recorded higher strain va