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Related Experiment Video

Updated: Jul 7, 2025

Designing CAD/CAM Surgical Guides for Maxillary Reconstruction Using an In-house Approach
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3D-printed patient specific surgical guides: Balancing accuracy with practicality.

Yiu Hin Kwan1, Dean Owyang1, Sean Wei Loong Ho1

  • 1Department of Orthopaedic Surgery, Tan Tock Seng Hospital, 11 Jalan Tan Tock Seng, 308433, Singapore.

Journal of Clinical Orthopaedics and Trauma
|December 22, 2023
PubMed
Summary

Optimizing three-dimensional (3D) printed surgical jigs for orthopaedic surgery requires specific parameters. A 15mm thick jig with a 120% sawblade slot height offers the best accuracy and usability for precise bone cuts.

Keywords:
BiomechanicsPatient-specificPrintingSurgical jigThree-dimensional

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Area of Science:

  • Orthopaedic Surgery
  • Biomechanical Engineering
  • Medical Device Design

Background:

  • Three-dimensional (3D) printing enables customized surgical cutting jigs in orthopaedics.
  • Optimal parameters for 3D printed surgical jig design are not well-established.
  • This study addresses the need for evidence-based guidelines in surgical jig creation.

Purpose of the Study:

  • To determine optimal parameters for 3D printed surgical jigs.
  • To enhance cutting accuracy and practical usability of surgical jigs.
  • To provide a guide for future surgical jig design and manufacturing.

Main Methods:

  • A biomechanical laboratory study was conducted.
  • Investigated the impact of jig thickness and cutting slot height on cutting accuracy.
  • Used 3D printed jigs and an oscillating sawblade on wooden blocks to simulate surgical cuts.

Main Results:

  • Cutting accuracy improved with increased jig thickness (15mm) and decreased slot height.
  • Optimal parameters for accuracy were a 15mm jig thickness and a 100% sawblade width slot height.
  • A 15mm jig thickness showed no significant accuracy difference up to 120% slot height.

Conclusions:

  • This study provides the first tangible parameters for reproducible surgical jig construction.
  • The ideal surgical jig balances accuracy and usability, recommended at 15mm thickness and 120% slot height.
  • The proposed parameters aim to improve surgical outcomes through precise cutting guides.