In-House 3D Printing and Model Processing Technique for Creating High-Fidelity Transparent Craniofacial Models

The use of high-fidelity stereolithographic models that accurately reflect patient-specific pathology has become commonplace in craniofacial surgery. Multiple studies have reported the use of commercially available three-dimensional (3D) printers that allow medical centers with limited resources to reconstruct 3D models comparable to industry-made counterparts. However, most models are printed using only a single filament, which portrays the surface craniofacial anatomy, but fails to highlight relevant intraosseous structures. This presents a significant limitation when used for preoperative planning and intraoperative guidance in surgical procedures requiring osteotomies, where knowledge of the precise location of critical structures is paramount to avoid injury. The authors report a novel technique for creating transparent 3D models of relevant intraosseous craniofacial anatomy at a cost that mitigates the financial burden of industrial 3D model or industrial 3D printer acquisition. Cases are presented to demonstrate the diverse applications of this technique, with accurate display of the tooth roots, the inferior alveolar nerve, and the optic nerve, to aid in preoperative planning of osteotomies. This technique enables production of low-cost, high-fidelity transparent 3D models with applications in preoperative planning for craniofacial surgery.