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A personalized 3D printed cranial shield using mirror-image modeling: design and clinical assessment
Zhongjie Shi1,2, Zhengbo Yuan1,3, Jie Chen4
1Department of Neurosurgery, The First Affiliated Hospital of Xiamen University, School of Medicine, Xiamen University, No.55 Zhenhai Road, Siming District, Xiamen, 361001, China.
3D Printing in Medicine
|July 1, 2025
Summary
A personalized 3D printed helmet offers cranial protection for decompressive craniectomy patients, improving physical safety and psychological well-being. This innovative device provides reliable shielding and enhances patient confidence during recovery.
Area of Science:
- Neurosurgery
- Biomedical Engineering
- Materials Science
Background:
- Decompressive craniectomy (DC) patients face risks from cranial defects, including physical vulnerability and psychological distress.
- Current protective measures for these patients are often inadequate.
- This study addresses the need for improved head protection in post-DC patients.
Purpose of the Study:
- To develop and evaluate a personalized, low-cost, 3D printed external head protection device.
- To assess the device's effectiveness in providing physical protection and improving patient-reported outcomes.
- To utilize mirror-image modeling for custom-fit cranial prosthetics.
Main Methods:
- A prospective study involving 58 patients undergoing DC was conducted.
- Participants were randomized into an observation group (custom 3D printed device) and a control group (no device).
- Patient-reported outcomes (satisfaction, social engagement, fear) and objective data (falls, adverse events) were collected using questionnaires and records.
Main Results:
- The 3D printed device showed good anatomical fit and structural reliability.
- The observation group reported significantly higher Visual Analog Scale (VAS) scores at 4 and 8 weeks post-discharge.
- No adverse skin reactions were reported; one fall in the observation group resulted in minor device damage but no head injury.
Conclusions:
- A personalized 3D printed helmet is a viable option for post-DC cranial protection.
- The device offers reliable mechanical shielding, custom fit, and good patient tolerance.
- This protective helmet can mitigate physical risks, enhance appearance confidence, and reduce anxiety, supporting early rehabilitation.
