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Vet Comp Orthop Traumatol
DOI: 10.1055/a-2654-8833
Original Research

Feasibility of Integrating Locking Plate System into Additively Manufactured Implants: A Mechanical Comparison of Three-Dimensional-Printed and Machined Locking Hole Threads

Kyu-Won Kang
1   Department of Veterinary Clinical Sciences, College of Veterinary Medicine and Research Institute for Veterinary Science, Seoul National University, Seoul, South Korea
,
Sunyoung Kim 
2   Department of Veterinary Clinical Sciences, College of Veterinary Medicine, Purdue University, West Lafayette, Indiana, United States
,
Byung-Jae Kang
1   Department of Veterinary Clinical Sciences, College of Veterinary Medicine and Research Institute for Veterinary Science, Seoul National University, Seoul, South Korea
3   BK21 FOUR Future Veterinary Medicine Leading Education and Research Center, Seoul National University, Seoul, South Korea
› Author Affiliations
Funding This research was supported by the Basic Science Research Program through the National Research Foundation of Korea, funded by the Ministry of Education (RS-2024-00407214) and by another National Research Foundation of Korea grant funded by the Korean government (MSIT; number 2023R1A2C1003001).
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Abstract

Objective

This study integrated a locking plate system into three-dimensional (3D)-printed implants and evaluated whether directly 3D-printed locking plate holes could achieve mechanical performance comparable to their machined counterpart.

Study Design

In vitro mechanical tests were performed to compare a 3D-printed 3.5-mm locking plate system with a commercially available variable-angle locking system (ARIX). Locking plate specimens (n = 90) were 3D printed from Ti6Al4V in three build orientations (0, 45 and 90 degrees). A torque limit test assessed the failure points under three screw insertion torques (0.6, 1.1 and 2.0 Nm) at two angles (0 and 15 degrees). The locked screw-and-plate constructs then underwent push-out testing, with a load applied parallel to the screw axis.

Results

At 2.0 Nm, all 3D-printed specimens failed due to thread deformation, whereas the ARIX system remained intact. Specimens printed at 0-degree orientation had the highest push-out strength, comparable to ARIX plates, while those printed at 90 degrees showed significantly lower strength. A higher insertion torque (1.1 Nm) improved the push-out strength regardless of screw angulation. Low torque with angled screws led to a substantial reduction in push-out strength.

Conclusion

The directly 3D-printed locking plate system achieved a comparable mechanical performance to machined counterparts when printed at 0-degree orientation, with appropriate torque. Optimal build orientation and careful control of insertion torque are crucial for maximizing the performance of 3D-printed locking plates.

Keywords

additive manufacturing - 3D-printed implant - insertion angle - insertion torque - locking plate system

Authors' Contribution

K-W.K. contributed to the conception of the study, study design, acquisition and interpretation of the data and drafted the manuscript. S-Y.K. contributed to the conception of the study and critically revised the manuscript. B-J.K. contributed to the conception of the study, study design and critically revised the manuscript. All authors contributed to editing the manuscript and approved the submitted version.




Publication History

Received: 16 October 2024

Accepted: 14 July 2025

Article published online:
23 July 2025

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