This research explores how titanium (Ti6Al4V) mini-implants (MIs) respond mechanically to different orthodontic forces using finite element analysis (FEA), with the goal of assessing their durability and functional performance under conditions mimicking clinical use. Applying forces within an optimal range is crucial for ensuring implant stability and protecting surrounding bone tissue. A standard MI (12 mm length, 2 mm diameter) was simulated in FEA. The mandible was reconstructed in three dimensions from CT scans using SpaceClaim 2023.1 and meshed with 10-node tetrahedral elements in ANSYS Workbench. Material characteristics were taken from the literature, and the implant–bone interface was modeled with nonlinear frictional contact. Forces of 2 N and 10 N were applied at a 30° angle to replicate typical clinical loading. The analysis focused on implant displacement, stress distribution (von Mises), strain levels, fatigue life, and safety margins. When loaded with 2 N, the implant showed minimal movement (0.0328 mm) and could withstand approximately 445,000 cycles with a safety factor of 4.84. Increasing the force to 10 N drastically reduced fatigue life to 1,546 cycles, while stress and strain concentrations rose sharply (6.468 × 10⁵ MPa), indicating a higher probability of implant failure and bone damage. These results identify the threshold at which excessive force jeopardizes MI stability and peri-implant bone integrity. The findings emphasize that maintaining orthodontic forces near 2 N is critical for prolonging MI lifespan and safeguarding bone. Forces beyond this optimal range, such as 10 N, significantly compromise implant durability and increase failure risk, highlighting the importance of careful force management in orthodontic treatments. This study offers practical insights to improve MI performance and clinical outcomes.
