Surgical fixation techniques for bone fracture healing are well established and effective; however, opportunities remain to improve both functional outcomes and the patient experience. The Biofiligree^® concept integrates medicine, engineering, and design by reimagining conventional osteosynthesis plates as both therapeutic and aesthetic devices. Inspired by traditional Portuguese filigree, these plates allow patient participation through personalized geometries, patterns, or engravings and may later be transformed into wearable jewellery after removal, preserving them as symbolic artefacts of recovery. This study introduces and biomechanically evaluates a novel calcaneal fixation plate incorporating the biofiligree geometry concept. A biofiligree plate was designed for calcaneus fracture fixation and manufactured in stainless steel 306L. Experimental testing was conducted on synthetic composite calcaneus bone models to simulate anatomical conditions and compare the new design with a standard commercial plate. The biofiligree plate, 2 mm thick, was fixed using five screws and two percutaneous screws positioned at 45° to compress the fracture line. Results demonstrated comparable biomechanical performance between both systems, with similar strain distributions and fracture stabilization. The biofiligree plate showed stresses around 430 MPa and fracture displacement below 0.7 mm. Fixation stiffness values were 1445 N/mm for intact calcaneus, 1065 N/mm for the commercial plate, and 725 N/mm for the biofiligree plate, indicating adequate support for bone healing.

Conventional osteosynthesis plates provide reliable fixation for bone fractures, but their design is predominantly functional and rarely addresses the patient’s emotional or symbolic relationship with the implanted device. This study introduces Biofiligree^®, a design-led fixation concept inspired by traditional Portuguese filigree, in which osteosynthesis plates are conceived simultaneously as biomedical implants and personalised artefacts that may later be transformed into wearable jewellery after fracture healing and plate removal. A proof-of-concept ulna fixation plate was developed and evaluated using finite-element analysis against an intact ulna and a conventional commercial plate. The Biofiligree^® plate produced a maximum displacement of 1.801 mm compared with 1.695 mm for the commercial plate, indicating a more compliant fixation system. Maximum von Mises stress reached approximately 600 MPa in the Biofiligree^® plate compared with 409 MPa in the commercial plate, revealing local stress concentrations associated with the open structural geometry. Maximum principal strain in bone was 3615 µε for the Biofiligree^® plate versus 1923 µε for the commercial plate, bringing tensile strain closer to the intact-ulna condition. Interfragmentary motion was 0.103 mm for the Biofiligree^® configuration and 0.052 mm for the commercial plate, corresponding to interfragmentary strains of 10.3% and 5.2%, respectively, for the initial 1 mm fracture gap. These results provide preliminary evidence of the biomechanical feasibility of the investigated Biofiligree^® geometry under the specific numerical conditions modelled, while also identifying the need for geometric optimisation around the fracture zone to reduce local stresses.