Wide Bone deffect Implant

[Tiligit994]

I am a PhD candidate in Biomedical Engineering, currently working on patient-specific bone implants for large defects in pelvic and cranial anatomical regions. Despite exploring several widely used software tools—including Blender, Meshmixer, and MeshLab—I continue to encounter significant challenges in achieving reliable results.

Among the tools I have tested, MeshLab (version 2025.07) has proven to be the most efficient for my workflow, enabling me to complete a substantial portion of my project. However, I am facing a critical difficulty when attempting to perform a Boolean difference operation to isolate the defective region from the non-defective model.

The primary issue arises during the alignment phase, where achieving accurate registration between the defective and reference (non-defective) models is inconsistent(as show in the first images). Consequently, when applying the Boolean difference operation, the output often incorrectly reproduces the entire non-defective model rather than isolating the intended defect region.

I would greatly appreciate guidance from anyone experienced in this area—either in resolving these issues within MeshLab or recommending alternative approaches or tools. If this process is inherently unreliable within MeshLab, I would also value your advice on more robust workflows or software solutions suitable for this type of application. I have attached the models for your imagination. if you want my personal contacts, email-atalaksew@gmail.com, Mobil-+215 923323042