Cranial Implant Assembly (Mesh + Bioceramic Shell)

Create a two-body composite assembly for a patient-specific cranial implant using a mesh-embedding design. Body 1 (titanium substructure): an open-cell mesh/lattice following the full skull defect surface, approximating a 78mm x 62mm patch of a sphere with 95mm radius of curvature. Hexagonal open-cell pattern, strut thickness 0.6mm, cell opening approximately 4mm across. Extend the mesh 5mm beyond the defect boundary on all sides to form a perimeter fixation tab that overlaps sound bone. Body 2 (ceramic shell): a calcium-phosphate (CaP) bioceramic shell that encapsulates and interpenetrates Body 1's open cells (the ceramic fills and keys through the mesh apertures rather than sitting as a separate bonded layer), covering the mesh's outer surface with a smooth continuous contour. Leave the perimeter fixation tabs of Body 1 exposed and free of ceramic for screw access. Features: 6 through-holes, 2.0mm diameter, evenly spaced around the exposed titanium tabs, positioned 3mm in from the tab edge. Assign material Ti-6Al-4V titanium alloy to Body 1 and calcium phosphate (hydroxyapatite-based) bioceramic to Body 2. Model Body 2 as fully interpenetrating Body 1's open cells, not as a simple edge lap joint. Unit: mm.

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