Bespoke Implants for Cranial Reconstructions: Preoperative to Postoperative Surgery Management System.

Area of Science:

• Neurosurgery
• Biomaterials Engineering
• Medical Device Design

Background:

• Traumatic brain injury (TBI) is a major global health issue, particularly in low- and middle-income countries.
• Craniectomy followed by cranioplasty is crucial for skull integrity and patient recovery after severe TBI.
• Current cranioplasty methods can be costly and may not always provide optimal fit.

Purpose of the Study:

• To develop and implement an integrative surgery management system for cranial reconstructions.
• To create accessible and cost-effective bespoke cranial implants.
• To evaluate the efficacy and safety of bespoke implants in patients undergoing cranioplasty.

Main Methods:

• Bespoke cranial implants were designed for three patients.
• Cranioplasty surgeries were performed using the custom implants.
• Dimensional accuracy and surface roughness of prototype implants were evaluated.
• Patient compliance and quality of life were assessed postoperatively.

Main Results:

• The study successfully designed and implemented bespoke cranial implants for three patients.
• Dimensional accuracy was confirmed across all three axes, with surface roughness measured (minimum Ra of 2.209 μm).
• Patients reported improvements in compliance and quality of life, with no short- or long-term complications observed.

Conclusions:

• The developed system offers an accessible and cost-effective solution for cranial reconstruction using bespoke implants.
• The use of bone cement materials and pre-planning reduced costs and intraoperative times compared to metal implants.
• The study demonstrates improved implant fit, patient satisfaction, and overall outcomes in cranioplasty procedures.