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An advanced prosthetic manufacturing framework for economic personalised ear prostheses
Rena L J Cruz1, Maureen T Ross1, Jacob Skewes1
1Institute of Health and Biomedical Innovation, Queensland University of Technology, Brisbane, QLD, Australia.
Scientific Reports
|July 12, 2020
Summary
This study introduces an advanced manufacturing framework for creating custom ear prostheses using 3D scanning and printing. This method significantly reduces costs and fabrication time compared to traditional techniques.
Area of Science:
- Biomaterials Engineering
- Medical Device Manufacturing
- Additive Manufacturing
Background:
- Craniofacial prostheses restore aesthetics for patients with tissue defects.
- Traditional fabrication methods are expensive, time-consuming, and skill-dependent.
- Existing techniques for prostheses result in high costs ($2,000-$7,000) and long labor times (14-15 hours).
Purpose of the Study:
- To present an advanced manufacturing framework for efficient fabrication of patient-specific ear prostheses.
- To offer a low-cost, high-accuracy alternative to traditional prostheses fabrication.
- To demonstrate the potential for translating this framework to other types of prostheses.
Main Methods:
- Utilized 3D scanning (structured light scanner) to capture ear geometry from six participants.
- Employed computer-aided design (CAD) to model patient-specific prostheses and 3-part negative molds.
- Fabricated molds using a low-cost desktop 3D printer and cast silicone prostheses; also developed an injection method with 3D printed ABS molds.
Main Results:
- Achieved an average cost of approximately $3 for consumables and $116 for 2 hours of labor for silicone prostheses.
- Developed an injection method with smoothed 3D printed ABS molds at a cost of approximately $155 for consumables and labor.
- Demonstrated significant cost and time savings compared to traditional hand-crafted prostheses.
Conclusions:
- The advanced manufacturing framework offers a non-invasive, cost-effective, and accurate alternative for ear prostheses.
- This approach is highly translatable to the fabrication of other craniofacial prostheses.
- Further cost reductions are anticipated with continued development of this manufacturing framework.
