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Full-Digital Workflow for Fabricating a Custom-Made Direct Metal Laser Sintering (DMLS) Mandibular Implant: A Case

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Area of Science:

  • Additive Manufacturing
  • Biomedical Engineering
  • Materials Science

Background:

  • Direct Laser Metal Sintering (DLMS) is an advanced additive manufacturing (AM) technique utilizing a laser to fuse metal powders layer by layer.
  • DLMS allows for the creation of intricate, patient-specific metal components from 3D CAD models.
  • Its application in fabricating custom titanium implants offers potential for complex reconstructive surgeries.

Observation:

  • A 67-year-old female patient with squamous cell carcinoma of the mandible required subtotal resection.
  • Previous conventional reconstruction methods were unsuccessful in restoring mandibular function.
  • A significant bone defect resulted from the extensive mandibular resection.

Findings:

  • A custom mandibular prosthesis was designed and fabricated using a digital workflow and DLMS technology.
  • The prosthesis successfully replaced the resected mandibular bone, addressing the extensive defect.
  • The reconstructed mandible supported a morse-taper dental prosthesis, reestablishing masticatory function.

Implications:

  • DLMS offers a viable solution for fabricating patient-specific implants in complex oral and maxillofacial reconstructions.
  • This technology can overcome limitations of conventional methods in cases of extensive bone defects.
  • Successful functional rehabilitation highlights the potential of AM in improving patient outcomes for cancer-related defects.