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Updated: May 1, 2026
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Treatment of Facial Deformities using 3D Planning and Printing of Patient-Specific Implants
Published on: May 23, 2020
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Patient-specific polyetheretherketone facial implants in a computer-aided planning workflow.
Godoberto Guevara-Rojas1, Michael Figl2, Kurt Schicho3
1PhD Student, Facial Esthetics Engineering Group, University Hospital of Cranio-Maxillofacial and Oral Surgery, Medical University of Vienna, Vienna, Austria.
Summary
This study introduces a workflow for custom polyetheretherketone (PEEK) implants in facial esthetics. The computer-aided design and manufacturing process, including soft tissue simulation, achieved high accuracy in patient-specific reconstructions.
Area of Science:
- Craniofacial surgery
- Biomaterials engineering
- Medical imaging
Background:
- Patient-specific implants (PSIs) offer personalized solutions for craniofacial reconstruction.
- Polyetheretherketone (PEEK) is a biocompatible material suitable for onlay grafting in facial esthetics.
- Virtual surgical planning enhances precision in complex reconstructive procedures.
Observation:
- A novel workflow integrating virtual osteotomy, subtraction volume, and soft tissue simulation for PEEK PSI design was developed.
- Computer-aided navigation facilitated precise intraoperative implant positioning.
- Photogrammetry captured 3D facial surface data post-surgery for error analysis.
Findings:
- The workflow demonstrated satisfactory intraoperative implant placement.
- High correspondence was observed between simulated and actual soft tissue surfaces.
- The mean total error (Hausdorff distance) was 0.81 ± 1.00 mm, with most deviations under 0.7 mm.
Implications:
- This computer-aided design, manufacturing, and surgery (CAD/CAM/CAS) workflow enables precise PEEK PSI fabrication and implantation for facial esthetic corrections.
- Complex surgical steps can be shifted to the pre-operative planning phase, potentially reducing surgical time and complexity.
- The method holds promise for improving outcomes in reconstructive and cosmetic facial surgery.
