Technical report: Rapid intraoperative reconstruction of cranial implants using additively manufactured moulds

During craniotomies, a portion of the calvarium or skull is removed to gain access to the intracranial space. When it is not possible to re-implant the flap, surgeons may repair the defect intraoperatively or at a later date. With larger defects being more difficult to repair intraoperatively, we investigated a method for the creation of patient-specific moulds for ad hoc bone flap reconstruction using rapid prototyping. Patient-specific moulds were created based on light scanned models of the defect, using custom software and rapid prototyping. Polymethylmethacrylate bone implants were created for three retrospective craniotomy cases and evaluated based on original flap and skull reconstruction accuracy. Bone implants created using our moulding method reconstruct the original flap and skull with an average reconstruction accuracy of 0.82 and 1.3 mm, respectively. Average skull reconstruction accuracy obtained by surgeons performing freehand implant reconstruction was 1.49 mm. Time needed to generate moulds was between 2 h and 45 min and 6 h and 20 min. Improvements to current printing technology will make this procedure technically feasible for future cranial procedures.