This study developed a customized surgical template under mechanical consideration for molar intrusion. Two finite element (FE) models were analyzed for the primary stability under 100 gf traction forces with one mini-screw inserted at the buccal side in horizontal and another in palatal side with two optional positions at 60° (P60) or 15° (P15) angles with inclination toward the molar occlusal surface. The surgical template was generated using rapid prototyping (RP) printing for the clinical application based on improved primarily stability model. The surrounding bone strains for models P15 and P60 were far lower than the bone remodeling critical value. Model P60 presented much lower micro-motion in the screw/bone interface and the screw head displacement than those values in model P15. Using FE analysis for biomechanical evaluation and combining with CT image, image superimposed method and CAD technique can fabricate accuracy/security customized surgical template for mini-screws with better primary stability.
