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Treatment of Facial Deformities using 3D Planning and Printing of Patient-Specific Implants
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Craniofacial Reconstruction by a Cost-Efficient Template-Based Process Using 3D Printing.

Bilal Msallem1, Fabian Beiglboeck1, Philipp Honigmann1

  • 1Clinic for Oral and Cranio-Maxillofacial Surgery, University Hospital of Basel, Basel, Switzerland; Medical Additive Manufacturing Research Group, Hightech Research Center, Department of Biomedical Engineering, University of Basel, Allschwil, Switzerland and Department of Hand Surgery, Kantonsspital Baselland, Liestal, Switzerland.

Plastic and Reconstructive Surgery. Global Open
|December 22, 2017
PubMed
Summary
This summary is machine-generated.

This study introduces a cost-effective method for creating custom craniofacial implants using 3D printing and silicone molding. This accessible technique allows for rapid, in-house fabrication, improving patient care, especially in resource-limited settings.

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Area of Science:

  • Biomaterials Engineering
  • Medical Device Manufacturing
  • Plastic and Reconstructive Surgery

Background:

  • Craniofacial defects cause significant aesthetic and functional issues, impacting patient well-being.
  • Patient-specific implants offer optimal solutions but are often limited by high costs.
  • There is a need for cost-efficient and accessible methods for producing patient-specific craniofacial implants.

Purpose of the Study:

  • To describe a fast and cost-efficient workflow for in-house manufactured patient-specific implants for craniofacial reconstruction.
  • To present a case study demonstrating the application of this workflow for supraorbital rim reconstruction.
  • To validate a hybrid manufacturing process combining additive manufacturing and silicone molding.

Main Methods:

  • A hybrid manufacturing process was developed, combining additive manufacturing (fused deposition modeling 3D printing) with manual silicone molding.
  • Computer-aided design (CAD) templates were 3D printed from thermoplastics.
  • Sterilized patient-specific molds were used intraoperatively to fabricate implants from polymethylmethacrylate (PMMA).

Main Results:

  • The workflow enables fast and cost-efficient in-house production of patient-specific craniofacial implants.
  • The entire mold fabrication process takes approximately 2 hours.
  • A successful reconstruction of a craniofacial defect involving the supraorbital rim was achieved using this method.

Conclusions:

  • The described hybrid manufacturing technique is simple, requires no advanced equipment, and minimizes financial expenses.
  • This reliable and easily adoptable technique is suitable for all healthcare facilities, particularly those with limited resources.
  • The workflow democratizes access to patient-specific treatments for craniofacial reconstruction and cranioplasty.