Design, printing optimization, and material testing of a 3D-printed nasal osteotomy task trainer

Area of Science:

• Medical Simulation
• 3D Printing in Medicine
• Surgical Education

Background:

• Simulation is crucial for training complex procedures like nasal osteotomy.
• 3D printing offers high-fidelity models but existing designs need improvement in cost and performance.
• Current practice relies on limited cadaveric specimens, hindering accessible training.

Purpose of the Study:

• To design an updated 3D-printable nasal osteotomy training model.
• To optimize the model for printability, usability, and fidelity.
• To compare 3D printing materials for bone equivalency in simulated surgery.

Main Methods:

• An updated nasal osteotomy model was designed, focusing on key structures and 3D printability.
• The model was printed using five different materials: PLA, ALGA, SimuBone, FibreTuff, and Durable V2.
• Facial plastic surgeons evaluated the models in a blinded, randomized study assessing tactile and audio feedback.

Main Results:

• An optimized 3D-printable nasal osteotomy model was successfully developed.
• SimuBone was subjectively rated as the most comparable material to human bone by physicians.
• The updated model demonstrated improved printability while maintaining critical anatomical detail.

Conclusions:

• A user-centered, low-cost, and printable midface model for surgical training was created.
• SimuBone material provides a more realistic tactile sensation compared to other tested materials.
• This updated model and material selection enhance simulation for nasal osteotomy practice.