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Smartphone Scanning and Machine Learning for Automated Presurgical 3D-printed Plate Fabrication From Cleft
Prasad Nalabothu1,2,3, Hemwati Nandan4, Srinivas Gosla Reddy4
1From the Department of Pediatrics Oral Health and Orthodontics, University Center for Dental Medicine UZB, Basel, Mattenstrasse 40, 4058 Basel, Switzerland.
Plastic and Reconstructive Surgery. Global Open
|September 29, 2025
Summary
This study introduces a new digital workflow for infant cleft lip and palate care. It uses a smartphone app and AI to create custom presurgical plates, improving comfort and accessibility.
Area of Science:
- Medical Technology
- Digital Health
- Craniofacial Surgery
Background:
- Accurate palatal impressions are crucial for infant cleft lip and palate (CLP) early intervention.
- Traditional plaster casting methods for palatal impressions are difficult and uncomfortable for newborns.
- Existing digital solutions often require expensive equipment, limiting accessibility.
Purpose of the Study:
- To present an innovative, accessible digital workflow for capturing palatal impressions in infants with CLP.
- To automate the design of presurgical orthopedic plates using a machine learning tool.
- To enhance patient comfort and streamline presurgical treatment for CLP.
Main Methods:
- Utilizing an open-source smartphone application for high-resolution 3D palatal scanning at the point of care.
- Implementing a custom machine learning tool to process 3D models and design presurgical plates with nasal stents.
- Developing a protocol for infant positioning, scanning technique, and data exportation.
Main Results:
- The digital workflow successfully captures accurate 3D palatal scans suitable for presurgical plate generation.
- The machine learning tool automates the design process, reducing manual intervention.
- The method is demonstrated to be simple, portable, cost-effective, and enhances patient comfort.
Conclusions:
- This digital workflow offers a reproducible and accessible alternative to traditional methods for presurgical plate fabrication in CLP care.
- The approach is particularly beneficial for resource-limited settings, modernizing early cleft treatment.
- The protocol enhances efficiency and patient safety, setting a new standard in pediatric craniofacial interventions.

