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Related Experiment Video

Updated: Jul 17, 2026

Treatment of Facial Deformities using 3D Planning and Printing of Patient-Specific Implants
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Treatment of Facial Deformities using 3D Planning and Printing of Patient-Specific Implants

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Novel 3-Dimensional Printed Lock-and-Key Cutting Guide Mechanism for Single-Stage Customized Reconstruction After

Marcio Yuri Ferreira1,2,3, Souvik Singha1,2,3, Shayan Huda1,2,3

  • 1Northwell, New Hyde Park, New York, USA.

Operative Neurosurgery (Hagerstown, Md.)
|July 15, 2026
PubMed
Summary

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Advanced materials (Deerfield Beach, Fla.)·2026

A novel 3D-printed lock-and-key guide enables single-stage skull reconstruction for neoplasms. This technique avoids intraoperative implant adjustments, improving outcomes for patients undergoing oncoplastic neurosurgery.

Area of Science:

  • Neurosurgery
  • Oncoplastic Surgery
  • 3D Printing in Medicine

Background:

  • Skull neoplasms often necessitate complex surgical resection and alloplastic reconstruction.
  • Single-stage reconstruction offers significant advantages by reducing patient burden.
  • Current custom cranial implant techniques frequently require intraoperative modifications.

Purpose of the Study:

  • To evaluate the efficacy and safety of a 3D-printed lock-and-key cutting guide for single-stage skull reconstruction.
  • To determine if this technique eliminates the need for intraoperative implant adjustments.
  • To assess outcomes in patients with skull neoplasms undergoing this novel approach.

Main Methods:

  • Retrospective analysis of prospectively registered patients undergoing single-stage reconstruction with a lock-and-key guide.
Keywords:
Cranial reconstructionCranioplastySingle-stage cranioplastySkull neoplasms

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  • The study included patients with various skull neoplasms requiring alloplastic cranioplasty.
  • Data collected on intraoperative, wound, and cranioplasty-related complications.

    • Main Results:

    • 14 patients (9 female, mean age 54) were included with a mean follow-up of 20 months.
    • Successful treatment was achieved in all cases, including meningiomas and metastases.
    • No intraoperative, wound, or cranioplasty complications occurred; no implant modifications were needed.

    Conclusions:

    • The 3D-printed lock-and-key guide is a feasible, effective, and safe technique for single-stage skull neoplasm reconstruction.
    • This approach obviates intraoperative implant modification, setting a new standard in oncoplastic neurosurgery.
    • The technique supports the refinement of neuro-oncological care towards oncoplastic neurosurgical principles.