In-house 3D Model Printing for Acute Cranio-maxillo-facial Trauma Surgery: Process, Time, and Costs

Three-dimensional (3D) printing is used extensively in cranio-maxillo-facial (CMF) surgery, but its usage is limited in the setting of acute trauma specifically, as delays in outsourcing are too great. Therefore, we developed an in-house printing solution. The purpose of this study was to describe this process for surgeons treating acute CMF trauma. This series describes the printing process, time required, and printing material costs involved for in-house printing applied to a variety of acute CMF trauma cases involving the upper, middle, and lower thirds of the face and skull. All consecutive patients requiring in-house 3D printed models in a level 1 trauma center for acute trauma surgery in mid-2019 were identified and analyzed. Nine patients requiring the printing of 12 in-house models were identified. The overall printing time per model ranged from 2 hours, 36 minutes to 26 hours, 54 minutes (mean = 7h 55 min). Filament cost was between $0.20 and $2.65 per model (mean = $0.95). This study demonstrates that in-house 3D printing can be done in a relatively short period of time, therefore allowing 3D printing usage for various acute facial fracture treatments. The rapid improvements in the usability of 3D software and printing technology will likely contribute to further adoption of these technologies by CMF-trauma surgeons.