Printing the Future—Updates in 3D Printing for Surgical Applications

Abstract

Three-dimensional (3D) printing is based on additive technology in which layers of materials are gradually placed to create 3D objects. The world of 3D printing is a rapidly evolving field in the medical industry as well as in most sectors of our lives. In this report we present current technological possibilities for 3D printing in the surgical field. There are different 3D printing modalities and much confusion among clinicians regarding the differences between them. Three-dimensional printing technologies can be classified based on the basic material used: solid, liquid, and powder. We describe the main printing methods from each modality and present their advantages while focusing on their applications in different fields of surgery, starting from 3D printing of models for preoperative planning up to patient-specific implants (PSI). We present the workflow of 3D printing for the different applications and our experience in 3D printing surgical guides as well as PSI. We include examples of 3D planning as well as clinical and radiological imaging of cases. Three-dimensional printing of models for preoperative planning enhances the 3D perception of the planned operation and allows for preadaptation of surgical instruments, thus shortening operation duration and improving precision. Three-dimensional printed PSI allow for accurate reconstruction of anatomic relations as well as efficiently restoring function. The application of PSI is expanding rapidly, and we will see many more innovative treatment modalities in the near future based on this technology.

A review on computer-aided design and manufacturing of patient-specific maxillofacial implants

“…Additionally, pre-fabricated modified implants and 3D models empowered specialists to observe a better plan for medical procedures before the real surgery. To accomplish the best fit of customized implants, specialists may require controlling instruments as PSI [86] or computer navigation [87] to duplicate the comparative resection plane as planned per planning software.…”

“…The importance of using 3D printing technology in a medical procedure is centered on these three classes: 3D surgical models, surgical implants and surgical guides. While models and implants can be made utilizing SLA and FDM, guides are printed using SLM, EBM or SLS technology [87].…”

Identifying a commercially-available 3D printing process that minimizes model distortion after annealing and autoclaving and the effect of steam sterilization on mechanical strength

“…Keywords: 3D printing, 3D printing materials, Additive manufacturing, Annealing, Autoclave, Medical devices, Optimization, Sterilization, Surgical instruments, Polylactic acid Background 3D printing is currently used in the medical field for a wide variety of purposes, including printing patient-personalized anatomical models to guide surgeons preoperatively, creating in-house anatomical models for medical student and resident training, and printing surgical instruments, prostheses, and implants [1][2][3][4][5][6][7]. 3D printed models have already been adopted to plan surgeries in fields including, but not limited to, cardiothoracic, craniomaxillofacial, hepatic, neonatal, neurological, ophthalmologic, orthopaedic, and plastic surgery [8][9][10][11][12][13][14][15][16][17][18][19].…”

Determination of the Elasticity Modulus of Additively Manufactured Wrist Hand Orthoses

“…The fused deposition modeling (FDM)/fused filament fabrication (FFF) method, which is popularly referred to as 3D printing using thermoplastics, is one of the most popular AM methods. Additively manufactured products have various applications including medical ones, for example, mid-surgery supplies [ 1 ], implants and endoprostheses [ 2 ] or individualized limb prostheses and orthoses (e.g., WHO, wrist-hand orthosis) with an openwork structure [ 3 ].…”