Generation of a 3D printed temporal bone model with internal fidelity and validation of the mechanical construct

To generate a rapid-prototyped temporal bone model from computed tomography (CT) data with a specific focus on internal anatomic fidelity.

Research ethics board-approved prospective cohort study.

Current iterations of a rapid-prototyped temporal bone model are complicated by absent void spaces and inconsistent bone density due to limited infiltrant exposure. The creation of a high-fidelity model allows surgical trainees to practice in a standardized and reproducible training environment. This learning paradigm will significantly augment resident understanding of surgical approaches and techniques to prevent adverse outcomes.

We describe a technique for generating internally accurate rapid-prototyped anatomical models with solid and hollow structures, including void spaces. The novel slicing algorithm digitally deconstructs a model into segments and permits removal of extraneous print material and allows infiltrant penetration of the entire bone structure. Precise reassembly is facilitated by digitally generated fiducials. Infiltrant of choice was determined by expert assessment and subjected to objective mechanical property assessment with comparison to cadaveric sheep bone.

The printed bone models are highly realistic. Void space representation was excellent with 88% concordance between cadaveric bone and the resultant rapid-prototyped temporal bone model. Ultimately, cyanoacrylate with hydroquinone was determined to be the most appropriate infiltrant for both cortical and trabecular simulation. The mechanical properties of all tested infiltrants were similar to real bone.

This model serves as an excellent replica of a human temporal bone for training and preoperative surgical rehearsal and can be dissected in a true-to-life fashion.