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. 2025 Aug 20;25(1):1341.
doi: 10.1186/s12903-025-06704-w.

Effect of different titanium mesh thicknesses on mechanical strength and bone stress: a finite element study

Betul Gedik  1 , Metin Berk Kasapoglu  2 , Gulce Ecem Dogancali  2 , Gozde Gokce Uckun  3 , Abdulkadir Burak Cankaya  2 , Mehmet Ali Erdem  2
Affiliations

Effect of different titanium mesh thicknesses on mechanical strength and bone stress: a finite element study

Betul Gedik et al. BMC Oral Health. .

Abstract

Background: This study aimed to investigate the influence of different titanium mesh thicknesses (0.1 mm, 0.2 mm, and 0.3 mm) on mechanical durability and stress distribution in guided bone regeneration using finite element analysis (FEA).

Methods: Three-dimensional mandibular bone models were reconstructed from cone-beam computed tomography (CBCT) data of a patient with a posterior alveolar defect. Custom titanium meshes with varying thicknesses were designed and virtually applied to the defect area. All models were subjected to a vertical force of 30 N to simulate masticatory loading. FEA simulations were performed using ALTAIR Hypermesh and OptiStruct software to evaluate von Mises stress distribution across the mesh, graft, and bone.

Results: The 0.1 mm mesh exhibited the highest stress concentrations (981.569 MPa), indicating a high risk of plastic deformation and potential graft damage (35.287 MPa). The 0.2 mm mesh provided moderate protection with improved stress distribution (mesh: 452.218 MPa, graft: 11.589 MPa). The 0.3 mm mesh showed the best mechanical performance, with the lowest stress values on both the mesh (226.205 MPa) and the graft (7.785 MPa). Bone stress remained below critical thresholds in all models.

Conclusion: Mesh thickness significantly affects the mechanical behavior and stress shielding capacity of titanium meshes in GBR applications. A thickness of 0.3 mm offers the most reliable mechanical performance. However, 0.2 mm meshes may serve as a viable alternative in cases requiring greater flexibility or lower cost, with caution toward borderline graft stress.

Keywords: Bone grafting; Finite element analysis; Guided bone regeneration; Mesh thickness; Titanium mesh.

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Conflict of interest statement

Declarations. Ethics approval and consent to participate: Ethical approval for this study was obtained from the Clinical Research Ethics Committee of Istanbul University, Faculty of Dentistry (Approval No: 2024/67), in accordance with the Declaration of Helsinki. Informed consent to participate was obtained from the participant in the study. Consent for publication: Written informed consent for publication was obtained from the patient. All data presented are anonymized, and no identifiable personal information is included. Competing interests: The authors declare no competing interests.

Figures

Fig. 1
Fig. 1
Preparation of models from tomography data in 3D Slicer software
Fig. 2
Fig. 2
Steps of designing Ti Mesh and bone graft on the defect area (1–4)
Fig. 3
Fig. 3
Force (1) and boundary conditions (2) models
Fig. 4
Fig. 4
Von Mises stress distrubution in the 0.1 mm mesh model
Fig. 5
Fig. 5
Von Mises stress distrubution in the 0.2 mm mesh model
Fig. 6
Fig. 6
Von Mises stress distrubution in the 0.3 mm mesh model
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