Objective Evaluation of Accuracy of Stereolithographic Models in Reconstruction of Mandibular Defects

Functional reconstruction of oromandibular defects has long been a surgical challenge. In recent years, computer-aided design (CAD)/computer-aided manufacturing (CAM) techniques have led to better evaluation of outcomes in terms of morphology and function. Previous studies comparing CAD/CAM to conventional methods have indicated significant improvement of technical accuracy with digital guidance, but final outcomes often still contain deviances of several millimeters. The purpose of this study was to morphometrically compare preplanned scenario with the stereolithographic model.

A prospective study composed of 15 patients with any pathology or defect who underwent computer-assisted mandibular reconstruction with vascularized free fibula flap were evaluated. Morphometric assessment from mental foramen to mental foramen, gonion to gonion, gonion-gnathion and vertical length of the ramus on the 3D model measured using digital caliper was compared with that of 3D CT data obtained using Osteo 3D proprietary software using the independent t test.

Descriptive statistics with frequency, percentage, mean and standard deviation was taken. The statistical analysis indicate that the comparisons of measuring the reference points on the 3D CT and 3D models do not have significant differences where p < 0.05. No significant interobserver differences were found (ICC = 0.99).

Stereolithographic models enable simulation of the resective and reconstructive phases, prebending of reconstruction plates and fabrication of surgical guides and it also confers reproducible precision and accuracy for free fibular mandibular reconstruction.

The online version contains supplementary material available at 10.1007/s12663-024-02178-5.