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Updated: Aug 19, 2025
Application of 3D Printing in the Construction of Burr Hole Ring for Deep Brain Stimulation Implants
Published on: September 7, 2019
Clinical Application of a Stereotactic Frame-Specific 3D-Printed Attachment for Deep Brain Stimulation Surgery
Jensen Ang1, John J Y Zhang2, Michael Yam3
1Department of Neurosurgery, National Neuroscience Institute, Singapore; Department of Neurosurgery, National Neuroscience Institute, Singapore General Hospital, Singapore.
Background:
Mispositioning of microelectrodes during deep brain stimulation surgery can incur serious complications for patients. Current practice of creating a burr hole for introduction of the microelectrode is done freehand and can cause trajectory misalignment. We aimed to create a sterilizable surgical adjunct to minimize error from burr hole placement.
Methods:
We designed and demonstrated clinical use of a 3D-printed surgical jig that can be mounted to the current Cosman-Roberts-Wells stereotactic frame. The jig allowed accurate placement of the perforating burr for creation of the burr hole.
Results:
Intraoperative usage of the jig in 11 patients who underwent bilateral deep brain stimulation microelectrode placement for Parkinson disease demonstrated high accuracy of microelectrode placement, with an average 1.18 mm deviation (range, 0-2.7 mm) from intended trajectories. No intraoperative complications were encountered.
Conclusions:
This proof-of-concept study highlights the utility of 3D-printed surgical adjuncts that are fully customizable and rapidly produced to improve current surgical practice. The jig reduced surgery duration, need for multiple trajectories, and risk of potentially devastating neurological complications. As demonstrated, 3D-printed devices are useful as surgical adjuncts to optimize safety and efficacy in deep brain stimulation surgeries.
