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Applied Sciences
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Mechanical Design and Modeling for Medical Devices and Simulators
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Mechanical Design and Modeling for Medical Devices and Simulators

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: 20 January 2027 | Viewed by 1645

Editors

Dr. Antonio Marzola

E-Mail Website
Guest Editor
Department of Industrial and Information Engineering and Economics, University of L’Aquila, 67100 L’Aquila, Italy
Interests: additive manufacturing; CAD; reverse engineering; medical image analysis; statistical shape modeling; feature recognition; 3D modeling; medical device design
Dr. Francesco Buonamici

E-Mail Website
Guest Editor
Department of Industrial Engineering, University of Florence (DIEF), 50139 Florence, Italy
Interests: additive manufacturing; reverse engineering; 3D modeling; virtual prototyping; CAD; design for additive manufacturing; patient-specific devices
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Technological innovation in design, 3D modeling and manufacturing is transforming the medical field. Advanced computational tools, artificial intelligence, reverse engineering techniques applied to diagnostic images, hybrid modeling approaches and additive manufacturing make it possible to work with complex anatomical structures, as well as the development of patient-specific solutions. These technologies also support the creation of surgical simulators, providing accurate, safe and effective anatomical and biomechanical representations for training and preoperative planning.

This Special Issue invites original research and review articles on the design, modeling, validation, optimization and manufacturing of medical devices and simulators. We will also consider submissions detailing advancements in materials science for biomedical devices and high-fidelity surgical simulators, with a focus on achieving accurate mechanical, optical or imaging readout properties across various diagnostic and intraoperative data acquisition systems. The aim is to highlight the technological advances driving the next generation of medical solutions.

Dr. Antonio Marzola
Dr. Francesco Buonamici
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-anonymized peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • medical devices
  • surgical simulators
  • mechanical design
  • 3D modeling
  • computational modeling
  • patient-specific design
  • additive manufacturing
  • artificial intelligence
  • reverse engineering

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Published Papers (3 papers)

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Research

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17 pages, 9580 KB  
Article
Biomechanical Evaluation of Loading Variability and Bone Quality in Total Knee Arthroplasty: A Finite Element Sensitivity Study
by Selma Mulla, Bernardo Innocenti and Mattia Sisella
Appl. Sci. 2026, 16(13), 6731; https://doi.org/10.3390/app16136731 - 5 Jul 2026
Viewed by 388
Abstract
While total knee arthroplasty (TKA) is highly successful, wear, primary fixation stability and structural failure remain significant challenges, particularly in patients with diverse kinetic profiles and compromised bone. This study evaluates a fixed-bearing cruciate-retaining TKA prosthesis under extreme load variability in healthy and [...] Read more.
While total knee arthroplasty (TKA) is highly successful, wear, primary fixation stability and structural failure remain significant challenges, particularly in patients with diverse kinetic profiles and compromised bone. This study evaluates a fixed-bearing cruciate-retaining TKA prosthesis under extreme load variability in healthy and osteoporotic bone. Finite element simulations utilized ISO-standardized baseline gait cycle, scaling independently axial forces, antero-posterior forces, and rotational torque to 50% and 200%. Polyethylene insert stress, tibial stress, and bone–implant micromotion were evaluated to assess structural safety, load transfer, and primary stability. Kinetic variability directly influenced the stress magnitude and load transfer. Insert load distribution revealed a compartmental split (medial side bearing 47.6% to 60.9%) sensitive to force orientation and translational load magnitudes (axial and shear), but totally independent of rotational torque magnitude. While reduced bone quality did not significantly affect overall polyethylene stresses, it directly impacted primary stability. Osteoporotic conditions nearly doubled the total baseline interface micromotion (from 19 µm to 37 µm) and exhibited an absolute maximum of 63 µm under 200% axial load scaling. These findings highlight the necessity of definition of model parameters for careful preclinical planning for patients with compromised bone quality regarding prosthesis selection, fixation method and alignment. Full article
(This article belongs to the Special Issue Mechanical Design and Modeling for Medical Devices and Simulators)
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17 pages, 19520 KB  
Article
Design and Validation of a Novel Modular High-Fidelity Simulator for Pediatric Percutaneous Tracheotomy Using the Frova Screw Technique
by Gaia Vannetti, Marta Mencarelli, Margherita Brogi, Luca Puggelli, Roberto Baggi, Stefano Avenali, Marco Di Mitri, Yary Volpe and Paola Serio
Appl. Sci. 2026, 16(9), 4556; https://doi.org/10.3390/app16094556 - 6 May 2026
Viewed by 489
Abstract
Percutaneous tracheotomy represents a critical airway procedure, yet training opportunities in pediatric patients remain limited due to the low incidence and high risk associated with the procedure. Simulation-based training plays a key role in enabling physicians to develop procedural skills in a safe [...] Read more.
Percutaneous tracheotomy represents a critical airway procedure, yet training opportunities in pediatric patients remain limited due to the low incidence and high risk associated with the procedure. Simulation-based training plays a key role in enabling physicians to develop procedural skills in a safe environment. This study presents the design, fabrication, and validation of a high-fidelity physical simulator for pediatric percutaneous tracheotomy using the Frova screw technique. The simulator reproduces the anatomy of an eight-year-old patient in a hyperextended neck position, allowing rigid bronchoscope insertion, and includes relevant anatomical landmarks. The presence of a blood pocket enhances procedural realism. The modular design, with a reusable base and disposable cartridge, enables rapid reset between sessions while minimizing maintenance costs. Soft tissues were reproduced through silicone molding, while rigid components were fabricated using fused deposition modeling 3D printing. Validation was performed by 39 physicians using a structured five-point Likert scale questionnaire. The simulator achieved a mean score of 4.2/5, with item scores ranging from 3.6 to 4.7, indicating a high level of perceived realism, procedural fidelity, and educational value, as well as highlighting potential areas of improvement. These findings suggest that the proposed simulator is a useful tool for simulation-based education, with the potential to improve operator confidence and patient safety in complex airway emergencies. Full article
(This article belongs to the Special Issue Mechanical Design and Modeling for Medical Devices and Simulators)
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Review

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34 pages, 2140 KB  
Review
Mechanical Design Maturity and Validation Pathways of Patient-Specific Subperiosteal Implants for Oral and Maxillofacial Rehabilitation: A Scoping Review
by Luigi Angelo Vaira, Hareem Qadeer, Andrea Biglio, Jerome R. Lechien, Fabio Maglitto, Giuseppe Consorti, Stefania Troise, Giulio Cirignaco, Giovanni Salzano, Valentino Vellone, Łukasz Woźniak, Marco Roy and Giacomo De Riu
Appl. Sci. 2026, 16(15), 7721; https://doi.org/10.3390/app16157721 - 3 Aug 2026
Viewed by 191
Abstract
Contemporary patient-specific subperiosteal implants (SPIs) have re-emerged as digitally planned, additively manufactured solutions for oral and maxillofacial rehabilitation when conventional endosseous implants are limited by severe atrophy, anatomical constraints, or reconstructive defects. Unlike conventional implants, SPIs behave as fixation-based skeletal frameworks whose performance [...] Read more.
Contemporary patient-specific subperiosteal implants (SPIs) have re-emerged as digitally planned, additively manufactured solutions for oral and maxillofacial rehabilitation when conventional endosseous implants are limited by severe atrophy, anatomical constraints, or reconstructive defects. Unlike conventional implants, SPIs behave as fixation-based skeletal frameworks whose performance depends on passive fit, screw fixation, anchorage, framework architecture, material properties, manufacturing accuracy, and prosthetic load transfer. This scoping review evaluated the maturity of mechanical design and validation evidence for contemporary SPIs. Following a predefined internal protocol and PRISMA-ScR, MEDLINE/PubMed, Scopus, Web of Science, Embase, and the Cochrane Library were searched from inception to 13 June 2026. Reference-list screening and citation tracking supplemented the electronic search. Two reviewers independently screened records against predefined eligibility criteria. Data were charted using a predefined extraction form and synthesized descriptively by evidence type, engineering domain, validation stage, and translational status. No meta-analysis was undertaken because of methodological heterogeneity, and no formal risk-of-bias grading was applied. Across 65 included records, the evidence was dominated by descriptive technical studies and comparative computational analyses, whereas direct mechanical testing, fatigue assessment, manufacturing verification, and clinical correlation were limited. Finite element analysis was useful for comparing design alternatives and identifying stress concentrations, but models were heterogeneous and often insufficiently validated. Design modifications generally redistributed stress across the implant–prosthesis–bone system rather than reducing it globally. Titanium and Ti6Al4V were the most established framework materials, whereas polymeric, ceramic, and scaffold-assisted strategies remained preliminary. The principal contribution of this review is a cross-domain appraisal of progression from anatomical feasibility and comparative modeling to manufacturing verification, experimental testing, and clinical validation. An evidence map, minimum reporting checklist, and integrated validation pathway are provided to support reproducible device development. Full article
(This article belongs to the Special Issue Mechanical Design and Modeling for Medical Devices and Simulators)
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