Dimensional Error in Rapid Prototyping with Open Source Software and Low-cost 3D-printer

Area of Science:

• Biomedical Engineering
• Maxillofacial Surgery
• 3D Printing Technology

Background:

• Rapid prototyping models (RPMs) are crucial in craniofacial and maxillofacial surgery.
• Economic constraints in developing countries like Mexico limit access to advanced RPM technology.
• There is a need for cost-effective RPM solutions in resource-limited healthcare settings.

Purpose of the Study:

• To assess the dimensional accuracy of a low-cost fused deposition modeling (FDM) 3D printer for RPM creation.
• To evaluate the feasibility of using open-source software with affordable 3D printing technology for surgical planning.

Main Methods:

• A dry human mandible was scanned using computed tomography.
• 3D data were processed using open-source software to generate a digital model.
• A rapid prototype was fabricated using a low-cost FDM 3D printer (Tronxy P802MA).
• Linear measurements were taken to calculate absolute and relative dimensional differences.

Main Results:

• The mean absolute difference was 0.65 mm.
• The mean relative difference was 1.96%.
• Statistical analysis showed no significant difference (P = 0.96).

Conclusions:

• Low-cost FDM 3D printers combined with open-source software offer a viable and cost-effective solution for manufacturing RPMs.
• The dimensional accuracy achieved is comparable to more expensive technologies, making RPMs more accessible in developing countries.
• This approach can significantly benefit maxillofacial surgery applications, including orthognathic surgery, reconstructions, and implantology, in resource-limited settings.