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3D Printed Surgical Instruments: The Design and Fabrication Process.

Mitchell George1, Kevin R Aroom2, Harvey G Hawes2

  • 1University of Texas Health Science Center at Houston, Houston, TX, USA. mitchell.j.george@uth.tmc.edu.

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Summary

Functional 3D printed surgical instruments are feasible, offering advantages like rapid production and customization. This study demonstrates the viability of additive manufacturing for creating usable surgical tools through iterative design and testing.

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Area of Science:

  • Biomedical Engineering
  • Materials Science
  • Surgical Technology

Background:

  • Additive manufacturing, or 3D printing, enables direct creation of objects from digital files.
  • Recent advancements in 3D printing show potential for novel surgical instrument design.
  • This research explores the feasibility of 3D printing usable surgical instruments.

Purpose of the Study:

  • To investigate the feasibility of designing and fabricating functional 3D printed surgical instruments.
  • To evaluate the performance and ergonomic functionality of 3D printed surgical tools.
  • To identify areas for improvement in the design and manufacturing process.

Main Methods:

  • Surgical instrument designs (hemostats, needle drivers, etc.) created using SolidWorks.
  • 3D printing via selective laser sintering (SLS) with DuraForm EX plastic.
  • Evaluation by general surgeons, including simulated surgeries and cadaveric procedures.

Main Results:

  • Multiple functional and reproducible 3D printed surgical sets were developed.
  • Iterative design, production, and testing cycles averaged 3 days.
  • Each set required an average of 6 hours of SLS build time.

Conclusions:

  • 3D printed surgical instruments are functionally feasible.
  • Additive manufacturing offers advantages over traditional methods, including cost-effective complexity and faster production.
  • The process allows for surgeon-specific modifications to instrument design.