Design and Comparison of Custom Cranial Prostheses Made of Titanium and Polyether Ether Ketone Using the Finite Element Method

Cranioplasty is an effective method for reconstructing cranial defects to protect the brain and improve patients’ quality of life. The use of biocompatible implants such as titanium and polyether ether ketone (PEEK) has become a suitable alternative to traditional bone grafts due to their favorable mechanical and biological properties.In this study, the design and numerical analysis of two types of cranial implants made of titanium and PEEK were performed using the Finite Element Analysis (FEA) method. A 3D model of a patient's skull with a significant defect in the right parietal region was extracted from CT images using Mimics software. The implant was designed through reverse engineering and mirroring techniques in 3-Matic software. The results showed that maximum stresses in PEEK implants were generally higher than those in titanium ones. Under loads above 200 N, there was a potential for stress concentration and damage in the third region of the implant. Additionally, the stresses imposed on the bone tissue adjacent to the implant were lower than those on the prosthesis itself, indicating that the implant bears a greater share of the load. However, a mere numerical comparison of stresses with yield stress is insufficient for accurate failure prediction.The findings suggest that titanium implants absorb more stress themselves, thereby placing less pressure on the surrounding bone, whereas PEEK implants transfer stress more effectively to the bone tissue, leading to a more uniform stress distribution. Therefore, the selection of implant material should be based on the location, type of loading, and the patient’s clinical condition to ensure optimal mechanical performance and safety.