Finite element analysis and clinical study of chest wall reconstruction using carbon fiber artificial rib.

Carbon fiber composites are emerging as a promising new biomaterial for chest wall reconstruction implants due to their mechanical properties and biocompatibility. This work evaluates the biomechanics of carbon fiber artificial ribs using finite element analysis and clinical implementation. Static simulations of normal breathing process show the maximum stress on the implant is only 2.83 MPa, far below the material ultimate strength of 60 MPa, indicating the excellent fit for maintaining respiratory function. Dynamic collision simulations demonstrate the artificial rib model could withstand a 4 kg rigid object impact at 2 m/s without fracture. Reconstructing the artificial rib with a human rib in the finite element analysis model increases the overall stress tolerance. The impact force required for fracture increases 48% compared to the artificial rib alone, suggesting improved strength from rib integration. Clinically, 10 of 13 patients receiving the artificial rib implants show no significant loss of pulmonary function based on spirometry tests. Based on our findings, the combined simulations and clinical results validate the strong mechanical performance and biocompatibility of the carbon fiber artificial ribs for chest wall reconstruction under static and dynamic loading while maintaining normal respiratory function.

Synthesis, structure, and properties of carbon/carbon composites artificial rib for chest wall reconstruction.

In this work, braided carbon fiber reinforced carbon matrix composites (3D-C/C composites) are prepared by chemical vapor infiltration process. Their composite structure, mechanical properties, biocompatibility, and in vivo experiments are investigated and compared with those of traditional 2.5D-C/C composites and titanium alloys TC4. The results show that 3D-C/C composites are composed of reinforced braided carbon fiber bundles and pyrolytic carbon matrix and provide 51% open pores with a size larger than 100 µm for tissue adhesion and growth. The Young's modulus of 3D-C/C composites is about 5 GPa, much smaller than those of 2.5D-C/C composites and TC4, while close to the autogenous bone. 3D-C/C composites have a higher tensile strength (167 MPa) and larger elongation (5.0%) than 2.5D-C/C composites (81 MPa and 0.7%), and do not show obvious degradation after 1 × 106 cyclic tensile loading. The 3D-C/C composites display good biocompatibility and have almost no artifacts on CT imaging. The in vivo experiment reveals that 3D-C/C composites artificial ribs implanted in dogs do not show displacement or fracture in 1 year, and there are no obvious proliferation and inflammation in the soft tissues around 3D-C/C composites implant. Our findings demonstrate that 3D-C/C composites are suitable for chest wall reconstruction and present great potentials in artificial bones.