Bone plates are essential for providing mechanical support during the healing of bone fractures by adapting to the biochemical environment. The surface quality of bone plates plays a vital role in their sustainability under adverse conditions. Magnetorheological Finishing (MRF) is an advanced surface finishing process that provides high surface finishing without disturbing the polished surface topography. However, while mapping to the workspace has a hole or pocket feature, the Magnetorheological (MR) fluid is not stable and gets trapped inside. Hence, a Feature-based hybrid MRF planning system is developed to overcome the challenge during MRF. The final average surface roughness (Ra) value of 21.56 nm from its initial roughness value of 324.12 nm is achieved on the polished surface bone plate made of Ti–6Al–4V. The enhancement in the surface characteristics of the MRF polished surface leads to the biomaterial's enhanced wear and corrosion resistance.
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