Comparative evaluation of personalized 3D-printed scaffold-driven double-barrel fibula flap for the reconstruction of segmented mandibular defects

•The scaffold-driven DBFF for mandibular reconstruction, by using scaffold filled with bone graft combined with fibula flaps.•The biomechanical behavior of 3D-printed porous titanium scaffolds with different design parameters was investigated by FEA.•Biomechanical differences of fibula, articular disc, cortical and trabecular bone were investigated and compared.•The scaffold transmit mechanical stimulus to promote bone regeneration in bone grafts, achieving mandibular reconstruction.