Numerical optimization for selecting the optimal geometrical configuration of polymeric skin mesh.

Burn injuries pose a critical healthcare challenge, particularly third-degree burns, which often result in extensive tissue damage and high mortality rates worldwide. Effective treatment typically involves skin grafting, with mesh grafts enabling coverage of larger wound areas using limited donor skin. Although various mesh designs have been developed, the optimal geometric configuration to minimize mechanical stress remains under investigation. This study evaluates the mechanical efficiency of three distinct mesh patterns applied to silicone-based skin models, aiming to reduce average stress and determine the optimal Young’s modulus. Finite element analysis was conducted using ABAQUS, and a genetic algorithm implemented in Python was employed to identify the best-performing mesh configuration. Among the tested geometries, a rectangular mesh measuring 3.975 mm × 1.157 mm (arranged in a 3-row, 13-column layout) produced the lowest average stress (0.045 MPa) and a corresponding Young’s modulus of 0.174 MPa. These findings provide a computational foundation for refining skin mesh designs, with potential applications in creating mechanically favorable conditions for skin graft expansion in severe burn management.