Design and 3D printing of pelvis phantoms for cementoplasty

Percutaneous image-guided cementoplasty is a medical procedure for strengthening bones structurally altered by disease, such as osteolytic metastasis. This procedure involves injecting biocompatible liquid bone cement, through one or more trocars into the damaged bone. Within a few minutes the bone cement hardens and restores the rigidity of the bony structure. The introduction of this technique in the case of large cancellous bones, such as the pelvis, raises some practical issues such as: how to manage the flow of cement with variable viscosity over time and how to inject a large amount of cement under fluoroscopy to effectively restore the patient's ability to bear weight?

As a means of training for young practitioners to ensure maximal filling of a metastatic bone area, we have designed and manufactured a pelvic phantom capable of replicating cement diffusion in healthy and metastatic bone under fluoroscopic and computed tomography guidance.

The preliminary stage of the study consisted of an analysis of various lattice structures, with the objective of reproducing the haptic feedback experienced during the needle insertion and diffusion of cement within the trabecular bone. Cementoplasty tests were conducted by an experienced radiologist under fluoroscopy and CT guidance to evaluate the performance of the lattice structure. The initial analysis provided the groundwork for the design of the phantom pelvis, which was then evaluated against a patient case. The phantom was divided into two distinct components: a disposable section with lattice structure, intended for the injection of cement, and a reusable part representing the pelvic bones. Two additive manufacturing methods were selected for the production of the phantom: Stereolithography (SLA) for the lattice structure and Fused Deposition Modeling (FDM) for the pelvic bones. The disposable component was composed of different lattice structures, selected to best match the anatomic conditions of both healthy and diseased areas visible on the patient images. Subsequently, the performance of the phantom was validated against patient images through a cementoplasty test.

A total of 12 distinct lattice structures were subjected to three tests of cementoplasty. Stochastic lattices with 500 microns beam thickness and densities varying from 15% to 5% demonstrated the most effective replication of the needle haptic feedback, as well as the diffusion of the cement into healthy and osteolytic cancellous bone. These structures were then implanted in the phantom and validated against one patient case.

A methodology to design and manufacture a phantom dedicated to cementoplasty from patient images is proposed. Initially, a series of lattice structures, exhibiting diverse structure types, thicknesses, and densities, were evaluated to assess their capacity to accurately reproduce the haptic feedback of the needle and the diffusion of cement in the trabecular bone. Subsequent to the outcomes of these investigations, several structures were selected for the development of a phantom capable of accurately replicating a cementoplasty procedure under fluoroscopy and CT guidance. This phantom will enable the training of future practitioners on the procedure of cementoplasty in the pelvis.