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Patient-Specific 3D Models for Open Frontal Sinus Surgery: Enhancing Precision with Facial Mask-Guidance.

Melikşah Çakır1, Erdem Köroğlu1, Fatih Özdoğan1

  • 1University of Health Sciences Türkiye, Kocaeli City Hospital, Department of Otorhinolaryngology-Head and Neck Surgery, Kocaeli, Türkiye.

Turkish Archives of Otorhinolaryngology
|December 15, 2025
PubMed
Summary
This summary is machine-generated.

This study introduces a novel 3D-printed facial mask for enhanced accuracy in frontal sinus surgery navigation. The cost-effective system improved surgical planning and incision guidance, even when navigation systems failed.

Keywords:
Frontal sinusanatomyosteomaparanasal sinus diseasessurgical proceduresthree-dimensional printing

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Area of Science:

  • Neurosurgery
  • Medical Imaging
  • Biomedical Engineering

Background:

  • Precision in osteoplastic frontal sinus surgery is crucial.
  • Conventional navigation techniques have limitations.
  • Three-dimensional (3D) printing is emerging in surgical navigation.

Purpose of the Study:

  • To enhance the accuracy of 3D model navigation in frontal sinus surgery.
  • To develop a novel facial mask component for improved incision guide alignment.
  • To create a cost-effective and accessible patient-specific planning system.

Main Methods:

  • Utilized open-source software for CT scan segmentation.
  • Developed a novel custom-designed facial mask with a locking mechanism.
  • Employed desktop 3D printing with polylactic-acid for rapid, low-cost production.

Main Results:

  • The 3D-printed model with facial mask provided accurate incision guidance in a case of navigation failure.
  • 1:1 scale models facilitated surgical planning for a frontal sinus osteoma.
  • Surgeons reported improved anatomical orientation, confidence, and planning effectiveness.

Conclusions:

  • The novel facial mask component shows promise for enhancing 3D model navigation accuracy in frontal sinus surgery.
  • The system is cost-effective and accessible, usable alone or with conventional methods.
  • Further studies are needed to standardize production and validate clinical utility.