Rapid-printed Three-dimensional Models for Craniomaxillofacial Trauma.

Area of Science:

• Craniomaxillofacial surgery
• Medical 3D printing
• Surgical planning

Background:

• 3D printing enhances surgical planning by visualizing complex anatomy.
• Long 3D print times hinder its use in acute trauma reconstruction.
• This study investigated optimizing 3D printing for rapid surgical planning models.

Purpose of the Study:

• To identify variables affecting 3D print time.
• To produce rapid-printed models for prebending osteosynthesis plates.
• To enable 3D printing workflows in acute craniomaxillofacial trauma.

Main Methods:

• Optimized 3D printing variables (resolution, orientation, cropping) on mandibular and midface fracture models.
• Printed models using high-resolution and time-efficient protocols.
• Contoured fixation plates to models and CT scans, computing distances and volumes.

Main Results:

• Optimized models printed significantly faster (0.93-1.07 hours) vs. high-resolution (7.47-7.53 hours).
• Cropping, rotation, and reduced resolution decreased print time substantially.
• Minimal differences in plate-to-model distance (0.22-0.34 mm) and air volume (0.90-1.39 mm³).

Conclusions:

• Adjusting 3D model size, resolution, and position enables rapid fabrication.
• Surgical reconstruction models can be rapidly printed without sacrificing surface quality.
• Reduced printing times facilitate 3D printing for acute craniomaxillofacial trauma surgical planning.