Abstract: Objective To evaluate of the clinical value of preoperative digital design-assisted free fibular flap for reconstruction of different types of mandibular tissue defects using three-dimensional finite element analysis. Methods This retrospective analysis was conducted in 48 patients undergoing reconstruction of mandibular defects following tumor resection using free fibular flaps. In 24 of the cases, digital design of free fibular flap was performed before the operation (experimental group), and the other 24 patients with digital design of the flap served as the control group. At 1 year after the surgery, the patients underwent mandibular CT examination and a 3-dimensional finite element model of the mandible was constructed using Mimics, Geomagic, Solidworks and Ansys. The stress distribution on the reconstructed mandibles with the H, L, or LCL types of defects, classified according to the HCL classification method, was determined under specific constraints and load conditions and compared between the experimental and control groups. Results The operations were completed successfully in all the patients, and none of them had tumor recurrence at 1 year after the operation. On the reconstructed mandibles using free fibular flaps, the stress was concentrated mainly on the neck of the bilateral condyle, the anterior and posterior edges of the ascending mandibular ramus, and the connection between the posterior end of the fibula and the mandible. A large size of mandibular defects caused greater stress at the contralateral condyle. For L-shaped defects, the maximum stress at the healthy and ipsilateral condyle necks and transplanted fibula were significantly lower, while the stress level at the healthy side mandibular angle was significantly greater in the experimental group than in the control group (P<0.05). For LCL type defects, the maximum stress at the contralateral condyle neck was smaller but the stress in the condyle area on the affected side, the bilateral mandibular angle area and the fibula area were all significantly greater in the experimental group than in the control group (P<0.05). Conclusion Digital design of the free fibular flap improves the accuracy of reconstruction of mandibular defects and helps to achieve uniform stress distribution on the reconstructed mandible.

Key words: digital design; mandible defects; free fibula flap; finite element analysis