Abstract: Thoracic reconstructions are essential surgical techniques used to replace severely damaged tissues and restore protection to internal organs. In recent years, advancements in additive manufacturing have enabled the production of thoracic implants with complex geometries, offering more versatile performance. In this study, we investigated a design based on a spring-like geometry manufactured by laser powder bed fusion (LPBF), as proposed in earlier research. The biomechanical behavior of this design was analyzed using various isolated semi-ring-rib models at different levels of the rib cage. This approach enabled a comprehensive examination, leading to the proposal of several implant configurations that were incorporated into a 3D rib cage model with chest wall defects, to simulate different chest wall reconstruction scenarios. The results revealed that the implant design was too rigid for the second rib level, which therefore was excluded from the proposed implant configurations. In chest wall reconstruction simulations, the maximum stresses observed in all prostheses did not exceed 38% of the implant material’s yield stress in the most unfavorable case. Additionally, all the implants showed flexibility compatible with the physiological movements of the human thorax.

Key words: Chest wall reconstruction; Thoracic implant; Spring-like geometry; Semi-ring-rib model; Computational analysis

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