This study determines the relative effects of changes in osteoporosis condition, plate/screw design factors (plate angle/length/width/thickness and screw diameter) and fixation methods (screw number and screw length) on the biomechanical response of dorsal double plating (DDP) fixation at a distal radius fracture to determine the optimal design and evaluate its biomechanical strength using the dynamic fatigue test. Eighteen CAD and finite element (FE) models corresponding to a Taguchi L18 array were constructed to perform numerical simulations to simulate the mechanical responses of a DDP fixed in a simply distal radius fracture bone. The Taguchi method was employed to determine the significance of each design factor in controlling bone/plate/screw stress and distal fragment displacement under axial (100 N), bending (1 N m) and torsion (1 N m) loads. Simulation results indicated that the order rank to determine the mechanical response was the plate thickness, plate width, screw diameter, and number of screws. Dorsal intermediate (L) plate with 60 mm length, 1.8 mm thickness, 6.0 mm width and 2.8 mm diameter, 20 mm length dual-thread locking screw can be found for optimisation. The DDP, including an L plate with 0°, 30° and 60° angles and a straight I plate, were made with Ti6Al4V to fix onto the sawbones with three corresponding radius fractures to perform the dynamic testing. The specimens were oscillated with loads between 10 N and 150 N at 5 Hz for 20,000 cycles. The average stiffness in 20,000 test cycles was 425.7 N/mm, 461.1 N/mm and 532.1N/mm for the 0°, 30° and 60° constructs, respectively. No difference in stiffness was found in the same angled constructs throughout the 20,000 cycles of testing (p > 0.05). Lack of gross construct failures during cyclic testing and reasonable stiffness corroborated that our new constructs tested to date seem stable enough to support restricted post-operative loads.
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