Journal articles on the topic 'Maxillofacial Additive Manufactured Surgical Guides'
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Dérand, Per, Lars-Erik Rännar, and Jan-M. Hirsch. "Imaging, Virtual Planning, Design, and Production of Patient-Specific Implants and Clinical Validation in Craniomaxillofacial Surgery." Craniomaxillofacial Trauma & Reconstruction 5, no. 3 (September 2012): 137–43. http://dx.doi.org/10.1055/s-0032-1313357.
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The purpose of this article was to describe the workflow from imaging, via virtual design, to manufacturing of patient-specific titanium reconstruction plates, cutting guide and mesh, and its utility in connection with surgical treatment of acquired bone defects in the mandible using additive manufacturing by electron beam melting (EBM). Based on computed tomography scans, polygon skulls were created. Following that virtual treatment plans entailing free microvascular transfer of fibula flaps using patient-specific reconstruction plates, mesh, and cutting guides were designed. The design was based on the specification of a Compact UniLOCK 2.4 Large (Synthes®, Switzerland). The obtained polygon plates were bent virtually round the reconstructed mandibles. Next, the resections of the mandibles were planned virtually. A cutting guide was outlined to facilitate resection, as well as plates and titanium mesh for insertion of bone or bone substitutes. Polygon plates and meshes were converted to stereolithography format and used in the software Magics for preparation of input files for the successive step, additive manufacturing. EBM was used to manufacture the customized implants in a biocompatible titanium grade, Ti6Al4V ELI. The implants and the cutting guide were cleaned and sterilized, then transferred to the operating theater, and applied during surgery. Commercially available software programs are sufficient in order to virtually plan for production of patient-specific implants. Furthermore, EBM-produced implants are fully usable under clinical conditions in reconstruction of acquired defects in the mandible. A good compliance between the treatment plan and the fit was demonstrated during operation. Within the constraints of this article, the authors describe a workflow for production of patient-specific implants, using EBM manufacturing. Titanium cutting guides, reconstruction plates for fixation of microvascular transfer of osteomyocutaneous bone grafts, and mesh to replace resected bone that can function as a carrier for bone or bone substitutes were designed and tested during reconstructive maxillofacial surgery. A clinically fit, well within the requirements for what is needed and obtained using traditional free hand bending of commercially available devices, or even higher precision, was demonstrated in ablative surgery in four patients.
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Chakravarthy, Chitra, Daisy Aranha, Santosh Kumar Malyala, and Ravi S. Patil. "Cast Metal Surgical Guides: An Affordable Adjunct to Oral and Maxillofacial Surgery." Craniomaxillofacial Trauma & Reconstruction Open 5 (January 1, 2020): 247275122096026. http://dx.doi.org/10.1177/2472751220960268.
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Additive manufacturing or 3-dimensional (3D) printing technology has an incredulous ability to create complex constructs with high exactitude. Surgical guides printed using this technology allows the transfer of the virtual surgical plan to the operating table, optimizing aesthetic outcomes, and functional rehabilitation. A vast variety of materials are currently being used in medical 3D printing, including metals, ceramics, polymers, and composites. The guides fabricated with titanium have high strength, excellent biocompatibility, and are sterilizable but take time to print and are expensive. We have thus followed a hybrid approach to fabricate an inexpensive surgical guide using metal where the advantage of 3D printing technology has been combined with the routinely followed investment casting procedure to fabricate guides using nickel–chromium, which has all the advantages of a metal and is cost-effective.
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Tereshchuk, Sergey, Sergey Ivanov, Daniil Korabelnikov, and Vladimir Sukharev. "The use of additive technologies in reconstructive maxillofacial surgery." Russian Medical and Social Journal 1, no. 2 (September 30, 2019): 29–39. http://dx.doi.org/10.35571/rmsj.2019.2.003.
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Introduction. Modern technologies make it possible not only to plan reconstructive surgery virtually, but also to manufacture templates for resection and osteotomy, customized titanium plates based on the results of planning.
Objective. To analyze the results of application of additive technologies for planning and performing reconstructive operations in the Maxillofacial Surgery and Stomatology Center at Burdenko Main Military Clinical Hospital
Patients and Methods. 144 operations to eliminate different locations bone defects were performed in the Maxillofacial Surgery and Stomatology Center in 2007 - 2017. 136 patients (93%) had de-fects of the bones of the facial skeleton and the skull calvarium. In other cases, there were defects of the clavicle (2 patients), defects of the femur (2 patients), defects of the humerus (2 patients), a defect of the radius (1 patient), a defect of the navicular bone (1 patient).
Results. Flaps were used to close the defects in 87% of cases (125 patients), and alloplastic implants were utilized in 13% of cases (19 patients). Additive technologies were used in 85% (n = 123) cases for planning the operation to eliminate defects, as well as for manufacturing surgical models and templates. Clinical cases are considered as examples of the use of the additive technologies for planning and performing reconstructive operations to close bone defects of different locations.
The incidence of postoperative complications in the group of patients with facial skeleton and crani-al vault bones defects who underwent surgical interventions using templates was 26%, including minor complications - 17.5%, large - 8.5%. Among minor complications, hematomas (5%) and sup-puration (5%) of the recipient wound prevailed, less often similar complications were hematomas (4%) and suppuration (3%) of the donor wound. Large complications were represented by cases of complete (4%) or partial (5%) transplant necrosis.
During surgical interventions without a template, it took significantly longer than the average time of grafting and graft formation (212 ± 18.7 min) than during operations with a template, including with a guide for drilling (136 ± 12.6 min, p <0.001) and without a guide for drilling (160 ± 16.3 min, p <0.001).
Conclusion. The use of surgical models and templates during reconstructive operations shortens the time of the operation and reduces the number of postoperative complications.
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Zhang, Rong Feng, Peng Yun Wang, Ming Yang, Xuebo Dong, Xue Liu, Yiguang Sang, and An Tong. "Application of 3D Printing Technology in Orthopedic Medical Implant -Spinal surgery as an example." International Journal of Bioprinting 5, no. 2 (June 4, 2019): 3. http://dx.doi.org/10.18063/ijb.v5i2.168.
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Additive manufacturing has been used in complex spinal surgical planning since the 1990s and is now increasingly utilized to produce surgical guides, templates, and more recently customized implants. Surgeons report beneficial impacts using additively manufactured biomodels as pre-operative planning aids as it generally provides a better representation of the patient’s anatomy than on-screen viewing of computed tomography (CT) or magnetic resonance imaging (MRI). Furthermore, it has proven to be very beneficial in surgical training and in explaining complex deformity and surgical plans to patients/ parents. This paper reviews the historical perspective, current use, and future directions in using additive manufacturing in complex spinal surgery cases. This review reflects the authors’ opinion of where the field is moving in light of the current literature. Despite the reported benefits of additive manufacturing for surgical planning in recent years, it remains a high niche market. This review raises the question as to why the use of this technology has not progressed more rapidly despite the reported advantages – decreased operating time, decreased radiation exposure to patients intraoperatively, improved overall surgical outcomes, pre-operative implant selection, as well as being an excellent communication aid for all medical and surgical team members. Increasingly, the greatest benefits of additive manufacturing technology in spinal surgery are customdesigned drill guides, templates for pedicle screw placement, and customized patient-specific implants. In view of these applications, additive manufacturing technology could potentially revolutionize health care in the near future.
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Pieralli, Stefano, Benedikt Christopher Spies, Valentin Hromadnik, Robert Nicic, Florian Beuer, and Christian Wesemann. "How Accurate Is Oral Implant Installation Using Surgical Guides Printed from a Degradable and Steam-Sterilized Biopolymer?" Journal of Clinical Medicine 9, no. 8 (July 22, 2020): 2322. http://dx.doi.org/10.3390/jcm9082322.
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3D printed surgical guides are used for prosthetically-driven oral implant placement. When manufacturing these guides, information regarding suitable printing techniques and materials as well as the necessity for additional, non-printed stock parts such as metal sleeves is scarce. The aim of the investigation was to determine the accuracy of a surgical workflow for oral implant placement using guides manufactured by means of fused deposition modeling (FDM) from a biodegradable and sterilizable biopolymer filament. Furthermore, the potential benefit of metal sleeve inserts should be assessed. A surgical guide was designed for the installation of two implants in the region of the second premolar (SP) and second molar (SM) in a mandibular typodont model. For two additive manufacturing techniques (stereolithography [SLA]: reference group, FDM: observational group) n = 10 surgical guides, with (S) and without (NS) metal sleeves, were used. This resulted in 4 groups of 10 samples each (SLA-S/NS, FDM-S/NS). Target and real implant positions were superimposed and compared using a dedicated software. Sagittal, transversal, and vertical discrepancies at the level of the implant shoulder, apex and regarding the main axis were determined. MANOVA with posthoc Tukey tests were performed for statistical analyses. Placed implants showed sagittal and transversal discrepancies of <1 mm, vertical discrepancies of <0.6 mm, and axial deviations of ≤3°. In the vertical dimension, no differences between the four groups were measured (p ≤ 0.054). In the sagittal dimension, SLA groups showed decreased deviations in the implant shoulder region compared to FDM (p ≤ 0.033), whereas no differences in the transversal dimension between the groups were measured (p ≤ 0.054). The use of metal sleeves did not affect axial, vertical, and sagittal accuracy, but resulted in increased transversal deviations (p = 0.001). Regarding accuracy, biopolymer-based surgical guides manufactured by means of FDM present similar accuracy than SLA. Cytotoxicity tests are necessary to confirm their biocompatibility in the oral environment.
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Carfagni, Monica, Flavio Facchini, Rocco Furferi, Marco Ghionzoli, Lapo Governi, Antonio Messineo, Francesca Uccheddu, and Yary Volpe. "Towards a CAD-based automatic procedure for patient specific cutting guides to assist sternal osteotomies in pectus arcuatum surgical correction." Journal of Computational Design and Engineering 6, no. 1 (January 3, 2018): 118–27. http://dx.doi.org/10.1016/j.jcde.2018.01.001.
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Abstract Pectus Arcuatum, a rare congenital chest wall deformity, is characterized by the protrusion and early ossification of sternal angle thus configuring as a mixed form of excavatum and carinatum features. Surgical correction of pectus arcuatum always includes one or more horizontal sternal osteotomies, consisting in performing a V-shaped horizontal cutting of the sternum (resection prism) by means of an oscillating power saw. The angle between the saw and the sternal body in the V-shaped cut is determined according to the peculiarity of the specific sternal arch. The choice of the right angle, decided by the surgeon on the basis of her/his experience, is crucial for a successful intervention. The availability of a patient-specific surgical guide conveying the correct cutting angles can considerably improve the chances of success and, at the same time, reduce the intervention time. The present paper aims to propose a new CAD-based approach to design and produce custom-made surgical guides, manufactured by using additive manufacturing techniques, to assist the sternal osteotomy. Starting from CT images, the procedure allows to determine correct resection prism and to shape the surgical guide accordingly taking into account additive manufacturing capabilities. Virtually tested against three case studies the procedure demonstrated its effectiveness. Highlights Patient-specific surgical guide improves the chances of success in sternal osteotomy. A CAD-based approach to design and produce custom-made surgical guides is proposed. The proposed framework entails both a series of automatic and user-guided tasks.
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A, Manmadhachary, Santosh Kumar Malyala, Ravi Kumar Y., Haranadha Reddy M., and Adityamohan Alwala. "Design & Manufacturing of Implant for reconstructive surgery: A Case Study." KnE Engineering 2, no. 2 (February 9, 2017): 143. http://dx.doi.org/10.18502/keg.v2i2.608.
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<p>Additive Manufacturing (AM), also known as 3D printing is an emerging technology in oral & maxillofacial surgery with respect to reconstructive bone surgery. Such treatment protocols often require customized implants to fulfill the functional and aesthetic requirements. Currently, such customized implants are being manufactured using AM technology. This paper describes a mandible defect of oral & maxillofacial surgery. The fracture and defect of the mandible inferior border is one of the serious complications during alignment and fixing of the implant. Reconstruction of such defects is daunting tasks. The case report describes a method based on Computer Aided Design (CAD) and AM for individual design, fabrication and implantation of a mandible inferior border. A 40-year old male meet an accident with rash drive. The patient specific customized implant is designed with patient Computed Tomography (CT) data. The CT images in Digital Imaging and Communication in Medicine (DICOM) file format is used to develop a 3D CAD model of customized implant. The implant is designed to maintain the symmetry of mandible from right to left. The designed implant model is manufactured by Fused Deposition Modelling (FDM) techniques with a biocompatible material. The patient mandible prototype model was manufactured by AM process, which is helpful for pre-planning of surgical procedures. For these pre-planning surgical procedures, a perfect fit obtained during surgery. The patient ultimately regained reasonable mandible contour and appearance of the face. </p>
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Frizziero, Leonardo, Gian Maria Santi, Christian Leon-Cardenas, Giampiero Donnici, Alfredo Liverani, Francesca Napolitano, Paola Papaleo, et al. "An Innovative and Cost-Advantage CAD Solution for Cubitus Varus Surgical Planning in Children." Applied Sciences 11, no. 9 (April 29, 2021): 4057. http://dx.doi.org/10.3390/app11094057.
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The study of CAD (computer aided design) modeling, design and manufacturing techniques has undergone a rapid growth over the past decades. In medicine, this development mainly concerned the dental and maxillofacial sectors. Significant progress has also been made in orthopedics with pre-operative CAD simulations, printing of bone models and production of patient-specific instruments. However, the traditional procedure that formulates the surgical plan based exclusively on two-dimensional images and interventions performed without the aid of specific instruments for the patient and is currently the most used surgical technique. The production of custom-made tools for the patient, in fact, is often expensive and its use is limited to a few hospitals. The purpose of this study is to show an innovative and cost-effective procedure aimed at prototyping a custom-made surgical guide for address the cubitus varus deformity on a pediatric patient. The cutting guides were obtained through an additive manufacturing process that starts from the 3D digital model of the patient’s bone and allows to design specific models using Creo Parametric. The result is a tool that adheres perfectly to the patient’s bone and guides the surgeon during the osteotomy procedure. The low cost of the methodology described makes it worth noticing by any health institution.
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Kittur, M. A., N. Scott, P. L. Evans, and S. C. Hodder. "Setting up an ‘in house’ service to provide 3D computer planning and additive manufactured surgical guides for fibula free flaps." International Journal of Oral and Maxillofacial Surgery 44 (October 2015): e92. http://dx.doi.org/10.1016/j.ijom.2015.08.639.
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Grover, Chetna, Pankaj Dhawan, and Shivam Singh Tomar. "REDEFINING PROSTHODONTICS WITH 3D PRINTING." International Journal of Advanced Research 9, no. 07 (July 31, 2021): 1093–100. http://dx.doi.org/10.21474/ijar01/13193.
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Dentistry is amidst a digital revolution and patients are the definitive recipients of these innovative technological advancements. Three-dimensional (3D) printing is no more considered the future, but isthe reality for daily clinical practice. The term 3D printing, additionally referred as rapid prototyping, is commonly used to depict an additive manufacturing method which adds numerous layers under computerized control in order to create a three-dimensional object. Using this procedure, 3-Dimensional printed restorations, crowns, bridges, surgical guides and implants can be manufactured rapidly with extreme accuracy and precision. The benefits of this innovative technique exceed its drawbacks. 3D printing has prompted a change in digital dentistry with its broad learning, penetrating opportunities and a wide scope of applications. This article will facilitate an understanding of the digital workflow, methods and current uses of 3D printing in prosthetic dentistry.
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Scott, N., S. Molyvda, P. Evans, S. Hodder, and M. A. Kittur. "Experiences of setting up an ‘in house’ service to provide 3D computer planning and additive manufactured surgical guides for fibula free flaps." British Journal of Oral and Maxillofacial Surgery 53, no. 10 (December 2015): e66-e67. http://dx.doi.org/10.1016/j.bjoms.2015.08.089.
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Tilton, Maryam, Gregory S. Lewis, Michael W. Hast, Edward Fox, and Guha Manogharan. "Additively manufactured patient-specific prosthesis for tumor reconstruction: Design, process, and properties." PLOS ONE 16, no. 7 (July 14, 2021): e0253786. http://dx.doi.org/10.1371/journal.pone.0253786.
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Design and processing capabilities of additive manufacturing (AM) to fabricate complex geometries continues to drive the adoption of AM for biomedical applications. In this study, a validated design methodology is presented to evaluate AM as an effective fabrication technique for reconstruction of large bone defects after tumor resection in pediatric oncology patients. Implanting off-the-shelf components in pediatric patients is especially challenging because most standard components are sized and shaped for more common adult cases. While currently reported efforts on AM implants are focused on maxillofacial, hip and knee reconstructions, there have been no reported studies on reconstruction of proximal humerus tumors. A case study of a 9-year-old diagnosed with proximal humerus osteosarcoma was used to develop a patient-specific AM prosthesis for the humerus following tumor resection. Commonly used body-centered cubic (BCC) structures were incorporated at the surgical neck and distal interface in order to increase the effective surface area, promote osseointegration, and reduce the implant weight. A patient-specific prosthesis was fabricated using electron beam melting method from biocompatible Ti-6Al-4V. Both computational and biomechanical tests were performed on the prosthesis to evaluate its biomechanical behavior under varying loading conditions. Morphological analysis of the construct using micro-computed tomography was used to compare the as-designed and as-built prosthesis. It was found that the patient-specific prosthesis could withstand physiologically-relevant loading conditions with minimal permanent deformation (82 μm after 105 cycles) at the medial aspect of the porous surgical neck. These outcomes support potential translation of the patient-specific AM prostheses to reconstruct large bone defects following tumor resection.
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Beltrán, Natalia, David Blanco, Braulio José Álvarez, Álvaro Noriega, and Pedro Fernández. "Dimensional and Geometrical Quality Enhancement in Additively Manufactured Parts: Systematic Framework and A Case Study." Materials 12, no. 23 (November 28, 2019): 3937. http://dx.doi.org/10.3390/ma12233937.
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In order to compete with traditional manufacturing processes, Additive Manufacturing (AM) should be capable of producing medium to large batches at industrial-degree quality and competitive cost-per-unit. This paper proposes a systematic framework approach to the problem of fulfilling dimensional and geometric requirements for medium batch sizes of AM parts, which has been structured as a three-step optimization methodology. Firstly, specific work characteristics are analyzed so that information is arranged according to an Operation Space (factors that could have an influence upon quality) and a Verification Space (formed by quality indicators and requirements). Standard process configuration leads to characterization of the standard achievable quality. Secondly, controllable factors are analyzed to determine their relative influence upon quality indicators and the optimal process configuration. Thirdly, optimization of part dimensional and/or geometric definition at the design level is performed in order to improve part quality and meet quality requirements. To evaluate the usefulness of the proposed framework under quasi-industrial condition, a case study is presented here which is focused on the dimensional and geometric optimization of surgical-steel tibia resection guides manufactured by Laser-Power Bed Fusion (L-PBF). The results show that the proposed approach allows for part quality improvement to a degree that matches the initial requirements.
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Muallah, David, Philipp Sembdner, Stefan Holtzhausen, Heike Meissner, André Hutsky, Daniel Ellmann, Antje Assmann, Matthias C. Schulz, Günter Lauer, and Lysann M. Kroschwald. "Adapting the Pore Size of Individual, 3D-Printed CPC Scaffolds in Maxillofacial Surgery." Journal of Clinical Medicine 10, no. 12 (June 16, 2021): 2654. http://dx.doi.org/10.3390/jcm10122654.
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Three dimensional (3D) printing allows additive manufacturing of patient specific scaffolds with varying pore size and geometry. Such porous scaffolds, made of 3D-printable bone-like calcium phosphate cement (CPC), are suitable for bone augmentation due to their benefit for osteogenesis. Their pores allow blood-, bone- and stem cells to migrate, colonize and finally integrate into the adjacent tissue. Furthermore, the pore size affects the scaffold’s stability. Since scaffolds in maxillofacial surgery have to withstand high forces within the jaw, adequate mechanical properties are of high clinical importance. Although many studies have investigated CPC for bone augmentation, the ideal porosity for specific indications has not been defined yet. We investigated 3D printed CPC cubes with increasing pore sizes and different printing orientations regarding cell migration and mechanical properties in comparison to commercially available bone substitutes. Furthermore, by investigating clinical cases, the scaffolds’ designs were adapted to resemble the in vivo conditions as accurately as possible. Our findings suggest that the pore size of CPC scaffolds for bone augmentation in maxillofacial surgery necessarily needs to be adapted to the surgical site. Scaffolds for sites that are not exposed to high forces, such as the sinus floor, should be printed with a pore size of 750 µm to benefit from enhanced cell infiltration. In contrast, for areas exposed to high pressures, such as the lateral mandible, scaffolds should be manufactured with a pore size of 490 µm to guarantee adequate cell migration and in order to withstand the high forces during the chewing process.
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Buj-Corral, Irene, Aitor Tejo-Otero, and Felip Fenollosa-Artés. "Development of AM Technologies for Metals in the Sector of Medical Implants." Metals 10, no. 5 (May 23, 2020): 686. http://dx.doi.org/10.3390/met10050686.
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Additive manufacturing (AM) processes have undergone significant progress in recent years, having been implemented in sectors as diverse as automotive, aerospace, electrical component manufacturing, etc. In the medical sector, different devices are printed, such as implants, surgical guides, scaffolds, tissue engineering, etc. Although nowadays some implants are made of plastics or ceramics, metals have been traditionally employed in their manufacture. However, metallic implants obtained by traditional methods such as machining have the drawbacks that they are manufactured in standard sizes, and that it is difficult to obtain porous structures that favor fixation of the prostheses by means of osseointegration. The present paper presents an overview of the use of AM technologies to manufacture metallic implants. First, the different technologies used for metals are presented, focusing on the main advantages and drawbacks of each one of them. Considered technologies are binder jetting (BJ), selective laser melting (SLM), electron beam melting (EBM), direct energy deposition (DED), and material extrusion by fused filament fabrication (FFF) with metal filled polymers. Then, different metals used in the medical sector are listed, and their properties are summarized, with the focus on Ti and CoCr alloys. They are divided into two groups, namely ferrous and non-ferrous alloys. Finally, the state-of-art about the manufacture of metallic implants with AM technologies is summarized. The present paper will help to explain the latest progress in the application of AM processes to the manufacture of implants.
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Calvo-Haro, Jose Antonio, Javier Pascau, José Manuel Asencio-Pascual, Felipe Calvo-Manuel, Maria José Cancho-Gil, Juan Francisco Del Cañizo López, María Fanjul-Gómez, et al. "Point-of-care manufacturing: a single university hospital’s initial experience." 3D Printing in Medicine 7, no. 1 (April 22, 2021). http://dx.doi.org/10.1186/s41205-021-00101-z.
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Abstract Background The integration of 3D printing technology in hospitals is evolving toward production models such as point-of-care manufacturing. This study aims to present the results of the integration of 3D printing technology in a manufacturing university hospital. Methods Observational, descriptive, retrospective, and monocentric study of 907 instances of 3D printing from November 2015 to March 2020. Variables such as product type, utility, time, or manufacturing materials were analyzed. Results Orthopedic Surgery and Traumatology, Oral and Maxillofacial Surgery, and Gynecology and Obstetrics are the medical specialties that have manufactured the largest number of processes. Working and printing time, as well as the amount of printing material, is different for different types of products and input data. The most common printing material was polylactic acid, although biocompatible resin was introduced to produce surgical guides. In addition, the hospital has worked on the co-design of custom-made implants with manufacturing companies and has also participated in tissue bio-printing projects. Conclusions The integration of 3D printing in a university hospital allows identifying the conceptual evolution to “point-of-care manufacturing.”
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Juneja, Mamta, Jannat Chawla, Gerry Dhingra, Ishank Bansal, Sahil Sharma, Parveen Goyal, Gurvanit Lehl, Anand Gupta, and Prashant Jindal. "Analysis of additive manufacturing techniques used for maxillofacial corrective surgeries." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, April 16, 2022, 095440622210819. http://dx.doi.org/10.1177/09544062221081992.
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Patients with jaw deformities often lead a poor quality of life due to problems encountered during speech, mastication and aesthetics, which makes maxillofacial reconstructive/corrective surgery necessary. Surgeons find difficulty in visualizing complex facial anatomy; therefore, a method of viewing a physical 3D maxillofacial model is highly beneficial. Accurately reproduced 3D models of a patient’s maxillofacial structure assist in pre-planning of a surgical procedure. AM (Additive Manufacturing) allows effective reproduction of a digital image into a physical model, replicating actual facial anatomy, thereby providing an effective solution. Among the AM techniques, PolyJet, FDM (Fused Deposition Modelling), SLA (Stereolithography) and SLS(Selective-Laser-Sintering) are being used for such applications. Comparison of these techniques is presented to determine the most efficient technique in reproducing such models for dimensional accuracy and cost. 20 models of five patients with deformed maxillofacial structures were designed using CAD (Computer-Aided Design) from STL (Standard Triangulation Language) files obtained from CT (Computerized Tomography) scans, which were manufactured using the aforementioned techniques. These models were then analysed for dimensional accuracies by identifying nine critical landmarks within the maxillofacial structures. Overall weight of the models was also evaluated for a cost-effective manufacturing solution. Dimensional measurement results of the 3D printed models indicated a relative error trend as PolyJet<SLA<SLS<FDM while material cost expenditure involved during 3D printing of these models indicated a trend as FDM<PolyJet<SLA<SLS, thereby recommending PolyJet as the most favoured AM technique for reproducing a maxillofacial structure. As a best practices guideline, incorporating AM for complex bone reconstruction procedures results in improved dimensional accuracies, reduced intraoperative time, reduced patient’s exposure to anaesthesia and ultimately an improved aesthetic outcome to the patient.