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Updated: Apr 28, 2026
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Three-Dimensional Reconstruction of Orbital Fractures
Published on: May 16, 2025
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Personalized 3D-Printed Hybrid PDMS and PEEK Implants for Revisional Orbitomaxillary Reconstruction: A Translational
Goran Marić1, Darko Solter2, Blanka Doko Mandić1
1Department of Ophthalmology, Univeristy Hospital Center Sestre Milosrdnice, Vinogradska Cesta 29, 10000 Zagreb, Croatia.
Journal of Functional Biomaterials
|April 27, 2026
Summary
This study introduces a hybrid biomaterial approach for complex orbitomaxillary reconstruction, combining rigid polyetheretherketone (PEEK) and flexible polydimethylsiloxane (PDMS) implants. This personalized strategy successfully restored facial structure and volume, offering a promising solution for craniofacial defects.
Area of Science:
- Biomaterials Science
- Craniofacial Surgery
- Medical Device Engineering
Background:
- Complex orbitomaxillary defects necessitate biomaterials offering structural stability and accurate facial contour restoration.
- Rigid polymers like PEEK provide mechanical support but lack viscoelasticity for soft tissue mimicry.
- Existing reconstruction methods may not fully address both structural integrity and volumetric augmentation.
Purpose of the Study:
- To present a translational revision case using a hybrid biomaterial approach for orbitomaxillary reconstruction.
- To evaluate the efficacy of combining 3D-printed PEEK and patient-specific PDMS implants.
- To demonstrate the potential of PDMS as a permanent implant for volumetric restoration in craniofacial surgery.
Main Methods:
- Utilized CT segmentation and contralateral mirroring for personalized reconstruction planning.
- Employed CAD/CAM techniques to design patient-specific implants: rigid PEEK for orbital support and flexible PDMS for malar augmentation.
- Performed revision surgery involving hardware removal, muscle release, and anatomical restoration.
Main Results:
- Achieved stable implant positioning and sustained orbitomaxillary stability postoperatively.
- Demonstrated successful anatomical reconstruction and facial symmetry restoration.
- Observed persistent functional sequelae (strabismus) addressed in a staged manner, leading to satisfactory ocular alignment.
Conclusions:
- The hybrid biomaterial approach effectively combines the complementary roles of rigid (PEEK) and elastic (PDMS) polymers in craniofacial reconstruction.
- Patient-specific PDMS implants show translational potential as a permanent material for volumetric and contour restoration.
- Personalized, hybrid implant strategies offer a viable solution for complex orbitomaxillary defects, though functional sequelae may require staged management.
