Optimizing Miniscrew Stability: A Finite Element Study of Titanium Screw Insertion Angles

This study aimed to evaluate how different insertion angles of titanium orthodontic miniscrews (30°, 45°, and 90°) influence stress distribution and displacement in surrounding alveolar bone using three-dimensional finite element analysis (FEA), with a focus on biomechanical outcomes at the titanium–bone interface. The 90° insertion angle generated the highest stress in cortical bone (58.2 MPa) but the lowest displacement (0.023 mm), while the 30° angle produced lower stress (36.4 MPa) but greater displacement (0.052 mm). The 45° angle represented a compromise, combining moderate stress (42.7 MPa) and displacement (0.035 mm). This simulation-based study was conducted between January and April 2025 at the Department of Orthodontics, Kocaeli Health and Technology University. A standardized 3D mandibular bone model (2 mm cortical and 13 mm cancellous layers) was constructed, and Ti-6Al-4V miniscrews (1.6 mm × 8 mm) were virtually inserted at 30°, 45°, and 90°. A horizontal orthodontic load of 2 N was applied, and von Mises stress and displacement values were calculated in ANSYS Workbench. Stress patterns were visualized using color-coded maps. The 90° insertion angle generated the highest von Mises stress in cortical bone (50.6 MPa), with a total maximum stress of 58.2 MPa, followed by 45° (42.7 MPa) and 30° (36.4 MPa) insertions (p < 0.001). Stress was predominantly concentrated at the cortical entry point, especially in the 90° model. In terms of displacement, the 90° group exhibited the lowest mean displacement (0.023 ± 0.002 mm), followed by 45° (0.035 ± 0.003 mm) and 30° (0.052 ± 0.004 mm), with statistically significant differences among all groups (p < 0.001). The 45° angle showed a balanced biomechanical profile, combining moderate stress and displacement values, as confirmed by post hoc analysis. From a biomimetics perspective, understanding how insertion angle affects bone response provides insights for designing bio-inspired anchorage systems. By simulating natural stress dissipation, this study demonstrates that insertion angle strongly modulates miniscrew performance. Vertical placement (90°) ensures rigidity but concentrates cortical stress, whereas oblique placement, particularly at 45°, offers a balanced compromise with adequate stability and reduced stress. These results emphasize that beyond material properties, surgical parameters such as insertion angle are critical for clinical success.