Using rapid prototyping molds to create patient specific polymethylmethacrylate implants in cranioplasty

Area of Science:

• Neurosurgery
• Biomaterials Engineering
• Medical Device Design

Background:

• Cranioplasty is a frequent surgical procedure to repair skull defects.
• Patient-specific implants enhance cranioplasty outcomes but are often prohibitively expensive.
• Limited accessibility of custom implants hinders widespread adoption.

Purpose of the Study:

• To present a low-cost technique for fabricating patient-specific polymethylmethacrylate (PMMA) implants.
• To utilize rapid prototyping for creating custom mold templates for PMMA implants.
• To demonstrate the feasibility and efficacy of this novel approach in clinical settings.

Main Methods:

• Utilized patient CT-scans (pre- and post-craniotomy) for 3D computer-assisted design.
• Developed a 3D mold template via rapid prototyping.
• Employed the mold in the operating room for in-situ PMMA implant fabrication.
• Applied the technique to three clinical cases.

Main Results:

• Successfully created patient-specific PMMA implants using the novel low-cost method.
• The technique allowed for fast and easy in-operating-room implant construction.
• All three treated patients experienced positive outcomes with no reported complications.

Conclusions:

• The presented technique offers an accessible, low-cost alternative for patient-specific cranioplasty implants.
• Rapid prototyped molds enable efficient fabrication of PMMA implants.
• This method holds promise for improving cranioplasty treatment accessibility and outcomes.