Comparison of 3D-printed and laboratory-fabricated Hyrax on stress distribution and displacement of the maxillary complex: a 3D finite element study

Abstract Objective To analyze and compare the effects of a traditional laboratory-fabricated Hyrax expander (T-Hyrax) and two different 3D-printed Hyrax expander models relative to tension points, force distribution, and areas of concentration in the craniofacial complex during maxillary expansion using finite element analysis. Materials and methods Three maxillary expanders with similar designs, but various alloys were modeled: a T-Hyrax, a fully printed Hyrax (F-Hyrax), and a hybrid printed Hyrax (H-Hyrax). The stress distributions and magnitude of displacements were assessed with a 5 mm expansion in a symmetrical finite element model. The areas of interest included the teeth, alveolar processes, midpalatal suture, nasal complex, circummaxillary sutures (CS), and the expanders themselves. Results The highest stress value (29.2 MPa) was found at the midpalatal suture of the F-Hyrax, while the lowest stress (0.90 MPa) was found at the temporozygomatic suture in the T-Hyrax. On average, the F-Hyrax increased stress at the CS by 24.76% compared with the T-Hyrax and H-Hyrax. The largest displacements were found at the upper incisor (U1) and anterior nasal spine (ANS). The findings indicated an average increase of 12.80% displacement at the CS using the F-Hyrax compared to the T-Hyrax. Conclusion The F-Hyrax exerts more stress and displacement on the maxilla than both the T-Hyrax and H-Hyrax, where the weak link appears to be the solder joint.