Accuracy of medical models made by additive manufacturing (rapid manufacturing)

The Accuracy of an Optical White Light Desktop 3D Scanner and Cone Beam CT Scanner Compared to a Multi-Slice CT Scanner to Digitize Anatomical 3D Models: A Pilot Study

Additive manufacturing, in combination with virtual surgery planning, leads to the predictability of complex surgical cases. To guarantee patient safety, three-dimensional (3D) print quality must be ensured and verified. The aim of this study is to compare the accuracy of an optical white-light desktop scanner (OWLDS) and a cone beam CT (CBCT) scanner to that of a multi-slice CT scanner (MSCT) for scanning and digitizing 3D anatomical models. Twenty-two removable parts of a CE-certified anatomical skull, used as a patient-specific surrogate in a clinical workflow, were each scanned by MSCT, CBCT, and OWLDS scanners. The accuracy of the scanning modalities was investigated through a part comparison analysis of the stereolithography (STL) files derived from the different scanning modalities. The high-resolution OWLDS STL files show the smallest overall surface match deviation, at 0.04 mm, compared to the MSCT STL files. The CBCT STL files show an overall deviation of 0.07 mm compared to the MSCT STL files. This difference between the scan modalities increases as the volume of anatomical models decreases. The OWLDS is a safe, cost-effective, user-friendly, and highly accurate scanning modality suitable for accuracy evaluation during the manufacturing process of in-house 3D models. For smaller models, high-resolution optical scans are recommended.

An exploratory study of the impact of CT slice thickness and inter-rater variability on anatomical accuracy of malunited distal radius models and surgical guides for corrective osteotomy

High-resolution CT images are essential in clinical practice to accurately replicate patient anatomy for 3D virtual surgical planning and designing patient-specific surgical guides. These technologies are commonly used in corrective osteotomy of the distal radius. This study evaluated how the virtual radius models and the surgical guides' surface that is in contact with the bone vary between experienced raters. Further, the discrepancies from the reference radius of surgical guides and radius models created from CT images with slice thicknesses larger than the reference standard of 0.625mm were assessed. Maximum overlap with radius model was measured for guides, and absolute average distance error was measured for radius models. The agreement between the lower-resolution guides surface and the raters' guide surface was evaluated. The average inter-rater guide surface overlap was -0.11mm [95% CI: -0.13-0.09]. The surface of surgical guides designed on CT images with a 1mm slice thickness deviated from the reference radius within the inter-rater range (0.03mm). For slice thicknesses of 1.25mm and 1.5mm, the average guide surface overlap was 0.12mm and 0.15mm, respectively. The average inter-rater radius surface variability was 0.03mm [95% CI: 0.025-0.035]. The discrepancy from the reference of all radius models created from CT images with a slice thickness larger than the reference slice thickness was notably larger than the inter-rater variability but, excluding one case, did not exceed 0.2mm. The results suggest that 1mm CT images are suitable for surgical guide design. While 1.25mm slices are commonly used for virtual planning in hand and forearm surgery, slices larger than 1mm may approach the limit of clinical acceptability. Discrepancies in radius models were below 1mm, likely below clinical relevance.

Designing and additive manufacturing of talus implant for post-traumatic talus avascular necrosis: a case study

New technologies in additive manufacturing and patient-specific CT-based custom implant designs make it possible for previously unimaginable salvage and limb-sparing operations a practical reality. This study presents the design and fabrication of a lattice-structured implant for talus replacement surgery. Our primary case involved a young adult patient who had sustained severe damage to the talus, resulting in avascular necrosis and subsequent bone collapse. This condition caused persistent and debilitating pain, leading the medical team to consider amputation of the left foot at the ankle level as a last resort. Instead, we proposed a Ti6Al4V-based patient-specific implant with lattice structure specifically designed for pan-talar fusion. Finite element simulation is conducted to estimate its performance. To ensure its mechanical integrity, uniaxial compression experiments were conducted. The implant was produced using selective laser melting technology, which allowed for precise and accurate construction of the unique lattice structure. The patient underwent regular monitoring for a period of 24 months. At 2-years follow-up the patient successfully returned to activities without complication. The patient's functional status was improved, limb shortening was minimized.

3D printed temporal bones for preoperative simulation and planning

OBJECTIVE

Demonstrate the utility of 3D printed temporal bone models in individual patient preoperative planning and simulation.

METHODS

3D models of the temporal bone were made from 5 pediatric and adult patients at a tertiary academic hospital with challenging surgical anatomy planned for cochlear implantation or exteriorization of cholesteatoma with complex labyrinthine fistula. The 3D models were created from CT scan used for preoperative planning, simulation and intraoperative reference. The utility of models was assessed for ease of segmentation and production and impact on surgery in regard to reducing intraoperative time and costs, improving safety and efficacy.

RESULTS

Three patients received cochlear implants, two exteriorization of advanced cholesteatoma with fistulas (1 internal auditory canal/cochlea, 1 all three semicircular canals). Surgical planning and intraoperative referencing to the simulations by the attending surgeon and trainees significantly altered original surgical plans. In a case of X-linked hereditary deafness, optimal angles and rotation maneuvers for cochlear implant insertion reduced operating time by 93 min compared to the previous contralateral side surgery. Two cochlear implant cases planned for subtotal petrosectomy approach due to aberrant anatomy were successfully approached through routine mastoidectomy. The cholesteatoma cases were successfully exteriorized without necessitating partial labyrinthectomy or labyrinthine injury. There were no complications.

CONCLUSION

3D printed models for simulation training, surgical planning and use intraoperatively in temporal bone surgery demonstrated significant benefits in designing approaches, development of patient-specific techniques, avoidance of potential or actual complications encountered in previous or current surgery, and reduced surgical time and costs.

Investigation of adhesion status of Candida species to the surface of resin materials produced at different angles with additive manufacturing

BACKGROUND

The aim of this study was to evaluate the adhesion of Candida glabrata, Candida albicans, Candida krusei, Candida parapsilosis and Candida tropicalis yeasts to disk-shaped resin materials produced from resin which used in the production of surgical guide with 0, 45 and 90-degrees printing orientations by Liquid Crystal Display additive manufacturing technology.

METHODS

Disk-shaped specimens were printed with surgical guide resin using the Liquid Crystal Display production technique in 3 printing orientations (0, 45 and 90-degrees). Surface roughness and contact angle values were evaluated. Real-Time PCR analysis was performed to evaluate Candida adhesion (C. glabrata, C. albicans, C. krusei, C. parapsilosis and C. tropicalis) Field emission scanning electron microscope (FESEM) images of the materials were obtained.

RESULTS

Specimens oriented at 45-degrees demonstrated higher surface roughness (P < .05) and lower contact angle values than other groups. No significant difference was found in the adhesion of C. glabrata, C. albicans, and C. parapsilosis among specimens printed at 0, 45, and 90-degrees orientations (P > .05). A higher proportion of C. krusei and C. tropicalis was found in the specimens printed at orientation degrees of 45 = 90 < 0 with statistical significance. Analyzing the adhesion of all Candida species reveals no statistical disparity among the printing orientations.

CONCLUSIONS

The surface roughness, contact angle, and adhesion of certain Candida species are affected by printing orientations. Hence, careful consideration of the printing orientation is crucial for fabricating products with desirable properties. In 45-degree production, roughness increases due to the layered production forming steps, whereas in 0-degree production, certain Candida species exhibit high adhesion due to the formation of porous structures. Consequently, considering these factors, it is advisable to opt for production at 90-degrees, while also considering other anticipated characteristics.

Assessment of the accuracy of 3D printed medical models through reverse engineering

The dimensional accuracy of additively manufactured (3D printed) medical models can be affected by various parameters. Although different methods are used to evaluate the accuracy of additively manufactured models, this study focused on the investigation of the dimensional accuracy of the medical model based the combination of reverse engineering (RE) and additive manufacturing (AM) technologies. Human femur bone was constructed from CT images and manufactured, using Fortus 450mc Industrial material extrusion 3D Printer. The additive manufactured femur bone was subsequently 3D scanned using three distinct non-contact 3D scanners. MeshLab was used for mesh analysis, while VX Elements was used for post-processing of the point cloud. A combination of the VX Inspect environment and MeshLab was used to evaluate the scanning performance. The deviation of the 3D scanned 3D models from the reference mesh was determined using relative metrics and absolute measurements. The scanners reported deviations ranging from -0.375 mm to 0.388 mm, resulting in a total range of approximately 0.763 mm with average root mean square (RMS) deviation of 0.22 mm. The results indicate that the additively manufactured model, as measured by 3D scanning, has a mean deviation with an average range of approximately 0.46 mm and an average mean value of around 0.16 mm.

Science mapping analysis of maxillofacial reconstruction over the last four decades

PURPOSE

This paper aims to provide a bibliometric analysis of the maxillofacial reconstruction literature over 40 years and to compare the data with previous studies.

METHODS

A bibliographical search for oral and maxillofacial surgery literature in maxillofacial reconstruction was conducted on Wef of Science. A graphic representation of authorship and keywords was created with VOSviewer. Mendeley and Microsoft Excel were used for tabulation and data visualization. Some statistical tests were performed with a 95 % confidence interval, which was considered significant.

RESULTS

A total of 7417 articles from specialized journals were included in the study. These articles received 138,493 citations from 63,390 other studies, with an average citation count of 18.67, and a very high H-index. A total of 2375 specific keywords were analyzed, covering a wide range of topics, with two noteworthy MeSH keywords that have recently gained prominence. A total of 33 journals were included in the study, with a mean Impact Factor of 2.404, indicating a relatively high influence in the subject area.

CONCLUSION

The high h-index reflects abundant and high-quality literature on maxillofacial reconstruction, with the United States leading in publication quantity. Emerging topics in maxillofacial reconstruction were discussed. These areas shape the discipline, driving advancements and offering opportunities for researchers and clinicians to contribute to progress and improve patient outcomes.

Automated 3-D Computer-Aided Measurement of the Bony Orbit: Evaluation of Correlations among Volume, Depth, and Surface Area

(1)The study aimed to measure the depth, volume, and surface area of the intact human orbit by applying an automated method of CT segmentation and to evaluate correlations among depth, volume, and surface area. Additionally, the relative increases in volume and surface area in proportion to the diagonal of the orbit were assessed. (2) CT data from 174 patients were analyzed. A ball-shaped mesh consisting of tetrahedral elements was inserted inside orbits until it encountered the bony boundaries. Orbital volume, area depth, and their correlations were measured. For the validation, an ICC was used. (3) The differences between genders were significant (p < 10-7) but there were no differences between sides. When comparing orbit from larger to smaller, a paired sample t-test indicated a significant difference in groups (p < 10-10). A simple linear model (Volume~1 + Gender + Depth + Gender:Depth) revealed that only depth had a significant effect on volume (p < 10-19). The ICCs were 1.0. (4) Orbital volume, depth, and surface area measurements based on an automated CT segmentation algorithm demonstrated high repeatability and reliability. Male orbits were always larger on average by 14%. There were no differences between the sides. The volume and surface area ratio did not differ between genders and was approximately 0.75.

Quality assurance of 3D-printed patient specific anatomical models: a systematic review

BACKGROUND

The responsible use of 3D-printing in medicine includes a context-based quality assurance. Considerable literature has been published in this field, yet the quality of assessment varies widely. The limited discriminatory power of some assessment methods challenges the comparison of results. The total error for patient specific anatomical models comprises relevant partial errors of the production process: segmentation error (SegE), digital editing error (DEE), printing error (PrE). The present review provides an overview to improve the general understanding of the process specific errors, quantitative analysis, and standardized terminology.

METHODS

This review focuses on literature on quality assurance of patient-specific anatomical models in terms of geometric accuracy published before December 4th, 2022 (n = 139). In an attempt to organize the literature, the publications are assigned to comparable categories and the absolute values of the maximum mean deviation (AMMD) per publication are determined therein.

RESULTS

The three major examined types of original structures are teeth or jaw (n = 52), skull bones without jaw (n = 17) and heart with coronary arteries (n = 16). VPP (vat photopolymerization) is the most frequently employed basic 3D-printing technology (n = 112 experiments). The median values of AMMD (AMMD: The metric AMMD is defined as the largest linear deviation, based on an average value from at least two individual measurements.) are 0.8 mm for the SegE, 0.26 mm for the PrE and 0.825 mm for the total error. No average values are found for the DEE.

CONCLUSION

The total error is not significantly higher than the partial errors which may compensate each other. Consequently SegE, DEE and PrE should be analyzed individually to describe the result quality as their sum according to rules of error propagation. Current methods for quality assurance of the segmentation are often either realistic and accurate or resource efficient. Future research should focus on implementing models for cost effective evaluations with high accuracy and realism. Our system of categorization may be enhancing the understanding of the overall process and a valuable contribution to the structural design and reporting of future experiments. It can be used to educate specialists for risk assessment and process validation within the additive manufacturing industry.

Trueness of five different 3D printing systems including budget- and professional-grade printers: An In vitro study

Problem

Several types of 3D printers with different techniques and prices are available on the market. However, results in the literature are inconsistent, and there is no comprehensive agreement on the accuracy of 3D printers of different price categories for dental applications.

Aim

This study aimed to investigate the accuracy of five different 3D printing systems, including a comparison of budget- and higher-end 3D printing systems, according to a standardized production and evaluation protocol.

Material and methods

A maxillary reference model with prepared teeth was created using 16 half-ball markers with a diameter of 1 mm to facilitate measurements. A reference file was fabricated using five different 3D printers. The printed models were scanned and superimposed onto the original standard tesselation language (.stl) file, and digital measurements were performed to assess the 3-dimensional and linear deviations between the reference and test models.

Results

After examining the entire surface of the models, we found that 3D printers using Fused filament fabrication (FFF) technology -120.2 (20.3) μm create models with high trueness but high distortion. Distortions along the z-axis were found to be the highest with the stereolithography (SLA)-type 3D printer at -153.7 (38.7) μm. For the 4-unit FPD, we found 201.9 (41.8) μm deviation with the digital light processing (DLP) printer. The largest deviation (-265.1 (55.4) μm) between the second molars was observed for the DLP printer. Between the incisor and the second molar, the best results were produced by the FFF printer with -30.5 (76.7) μm.

Conclusion

Budget-friendly 3D printers are comparable to professional-grade printers in terms of precision. In general, the cost of a printing system is not a reliable indicator of its level of accuracy.

An In Vivo Study to Compare the Clinical Effectiveness of Clear Retainer Made on a Conventional and a Digitally Fabricated Model Over a Six-Month Period After Debonding

Background With the advent of 3D printing, many more possibilities have arisen for treatment planning. 3D rapid prototyping has enabled us to see a whole other dimension that has helped us to give the best possible care for our patients. With more and more advancements being made in this subject, it becomes necessary to check the reliability of the equipment and its effectiveness in the management of the problem at hand. This original study was conducted with the aim of checking the accuracy, dimensional stability, and reliability of orthodontic retainers made on a conventional and digitally fabricated model over a six-month period after debonding. Material and methods The patients were selected from those who have completed fixed orthodontic mechanotherapy from the Department of Orthodontics and Dentofacial Orthopaedics, Sri Guru Ram Das Institute of Dental Sciences and Research, Sri Amritsar. Fifty patients received a clear retainer, which was fabricated for the upper and lower arch after removing the brackets. Patients were included in this study irrespective of their age groups. The manual method used a vacuum-forming machine to fabricate six retainers on stone models. In the digital method, new impressions were taken after three months, and digital models were obtained through 3D scanning and printing, followed by clear retainer fabrication. The data were gathered through a systematic process involving manual and digital methods for clear retainer fabrication and subsequent evaluation. The data obtained was computed for statistical evaluation and comparison. Results Mean and standard deviations of conventional (manual) and digital variables in the two groups were calculated. An ANOVA test was used to evaluate statistically significant differences for mesiodistal width and buccolingual width, and a post hoc Tuckey test was applied for multiple comparisons. The results indicated that most mesiodistal and buccolingual width measurements showed non-significant variations and exhibited a good correlation. Extraction space opening, assessed through an independent t-test for both the maxilla and mandible, also yielded non-significant and comparable results. Additionally, intra-operator and inter-operator measurements using a digital caliper demonstrated high agreement. Intra-class correlation (ICC) values exceeded 0.75, and inter-operator ICC results reflected a high level of agreement ranging from 0.8 to 0.99. Conclusion The primary objective of this study was to establish a correlation between the accuracy, dependability, and clinical efficacy of orthodontic retainers produced using both conventional and digitally created models. This investigation spanned a duration of six months following the removal of orthodontic brackets. The results showed that most of the statistically significant values were due to the inherent potential of the 3D printer for polymerization shrinkage, which, being a stereolithographic 3D printer, had a potential for a slight dimensional shift in the transverse dimension. However, the mean difference between all the models printed was slight and clinically insignificant.

Highly Reinforced Acrylic Resins for Hard Tissue Engineering and Their Suitability to Be Additively Manufactured through Nozzle-Based Photo-Printing

Mineralized connective tissues represent the hardest materials of human tissues, and polymer based composite materials are widely used to restore damaged tissues. In particular, light activated resins and composites are generally considered as the most popular choice in the restorative dental practice. The first purpose of this study is to investigate novel highly reinforced light activated particulate dental composites. An innovative additive manufacturing technique, based on the extrusion of particle reinforced photo-polymers, has been recently developed for processing composites with a filler fraction (w/w) only up to 10%. The second purpose of this study is to explore the feasibility of 3D printing highly reinforced composites. A variety of composites based on 2,2-bis(acryloyloxymethyl)butyl acrylate and trimethylolpropane triacrylate reinforced with silica, titanium dioxide, and zirconia nanoparticles were designed and investigated through compression tests. The composite showing the highest mechanical properties was processed through the 3D bioplotter AK12 equipped with the Enfis Uno Air LED Engine. The composite showing the highest stiffness and strength was successfully processed through 3D printing, and a four-layer composite scaffold was realized. Mechanical properties of particulate composites can be tailored by modifying the type and amount of the filler fraction. It is possible to process highly reinforced photopolymerizable composite materials using additive manufacturing technologies consisting of 3D fiber deposition through extrusion in conjunction with photo-polymerization.

Shear Strength of Repaired 3D-Printed and Milled Provisional Materials Using Different Resin Materials with and without Chemical and Mechanical Surface Treatment

The aim of this study was to assess the shear bond strength of 3D-printed and milled provisional restorations using various resin materials and surface finishes. There were 160 preliminary samples in all, and they were split into two groups: the milled group and the 3D-printed group. Based on the resin used for repair (composite or polymethylmethacrylate (PMMA)) and the type of surface treatment utilized (chemical or mechanical), each group was further divided into subgroups. The specimens were subjected to thermocycling from 5 °C to 55 °C for up to 5000 thermal cycles with a dwell time of 30 s. The mechanical qualities of the repaired material underwent testing for shear bond strength (SBS). To identify the significant differences between the groups and subgroups, a statistical analysis was carried out. Three-way ANOVA was used to analyze the effects of each independent component (the material and the bonding condition), as well as the interaction between the independent factors on shear bond strength. Tukey multiple post-hoc tests were used to compare the mean results for each material under various bonding circumstances. The shear bond strengths of the various groups and subgroups differed significantly (p < 0.05). When compared to the milled group, the 3D-printed group had a much greater mean shear bond strength. When compared to PMMA repair, the composite resin material showed a noticeably greater shear bond strength. In terms of surface treatments, the samples with mechanical and chemical surface treatments had stronger shear bonds than those that had not received any. The results of this study demonstrate the effect of the fabrication method, resin type, and surface treatment on the shear bond strength of restored provisional restorations. Particularly when made using composite material and given surface treatments, 3D-printed provisional restorations showed exceptional mechanical qualities. These results can help dentists choose the best fabrication methods, resin materials, and surface treatments through which to increase the durability and bond strength of temporary prosthesis.

Accuracy of Zygomatic Implant Placement Using a Full Digital Planning and Custom-Made Bone-Supported Guide: A Retrospective Observational Cohort Study

The aim of the study was to evaluate the accuracy of zygomatic implant placement using customized bone-supported laser-sintered titanium templates. Pre-surgical computed tomography (CT) scans allowed to develop the ideal virtual planning for each patient. Direct metal laser-sintering was used to create the surgical guides for the implant placement. Post-operative CT scans were taken 6 months after surgery to assess any differences between the planned and placed zygomatic implants. Qualitative and quantitative three-dimensional analyses were performed with the software Slicer3D, recording linear and angular displacements after the surface registration of the planned and placed models of each implant. A total of 59 zygomatic implants were analyzed. Apical displacement showed a mean movement of 0.57 ± 0.49 mm on the X-axis, 1.1 ± 0.6 mm on the Y-axis, and 1.15 ± 0.69 mm on the Z-axis for the anterior implant, with a linear displacement of 0.51 ± 0.51 mm on the X-axis, 1.48 ± 0.9 mm on the Y-axis, and 1.34 ± 0.9 mm on the Z-axis for the posterior implant. The basal displacement showed a mean movement of 0.33 ± 0.25 mm on the X-axis, 0.66 ± 0.47 mm on the Y-axis, and 0.58 ± 0.4 mm on the Z-axis for the anterior implant, with a linear displacement of 0.39 ± 0.43 mm on the X-axis, 0.42 ± 0.35 mm on the Y-axis, and 0.66 ± 0.4 mm on the Z-axis for the posterior implant. The angular displacements recorded significative differences between the anterior implants (yaw: 0.56 ± 0.46°; pitch: 0.52 ± 0.45°; roll: 0.57 ± 0.44°) and posterior implants (yaw: 1.3 ± 0.8°; pitch: 1.3 ± 0.78°; roll: 1.28 ± 1.1°) (p < 0.05). Fully guided surgery showed good accuracy for zygomatic implant placement and it should be considered in the decision-making process.

The Feasibility of Electromagnetic Navigation Technique to Achieve Preoperative Plan in Mandibular Angle Osteotomy

BACKGROUND

In contrast to the most commonly used optical navigation system, electromagnetic navigation has huge potential in operations with a narrow field. The purpose of this experiment was to test and confirm whether the electromagnetic navigation method the authors developed for mandibular angle osteotomy (MAO) met clinical requirements.

METHODS

Using a dental splint that could be repeatedly mounted on teeth, registration between surgical plan and actual field was performed automatically.

RESULTS

Navigation of MAO was first performed on 10 mandibular models. The position precision measured using a coordinate measuring machine was 1.30±0.61 mm. Then, a navigation experiment was performed on 4 patients. Accuracy in actual operation measured by the NDI pointing sensor was 1.89±0.76 mm. Our noninvasive automatic registration process reduced the surgical exposure time and eliminated the bias of the manual selection of registration points.

CONCLUSIONS

This preliminary study confirmed the feasibility of the electromagnetic navigation technique in terms of both applicability and accuracy in MAO surgery.

The Influence of Cone Beam Computed Tomography-Derived 3D-Printed Models on Endodontic Microsurgical Treatment Planning and Confidence of the Operator

INTRODUCTION

Currently, there are no studies evaluating the impact of 3-dimensional (3D) printed models on endodontic surgical treatment planning. The aims of this study were: 1) to determine if 3D models could influence treatment planning; and 2) to assess the effect of 3D supported planning on operator confidence.

MATERIALS

Endodontic practitioners (n = 25) were asked to analyze a preselected cone beam computed tomography (CBCT) scan of an endodontic surgical case and answer a questionnaire that elucidated their surgical approach. After 30 days, the same participants were asked to analyze the same CBCT scan. Additionally, participants were asked to study and to perform a mock osteotomy on a 3D printed model. The participants responded to the same questionnaire along with a new set of questions. Responses were statistically analyzed using chi square test followed by either logistic or ordered regression analysis. Adjustment for multiple comparison analysis was done using a Bonferroni correction. Statistical significance was set at ≤0.005.

RESULTS

The availability of both the 3D printed model and the CBCT scan resulted in statistically significant differences in the participants' responses to their ability to detect bone landmarks, predict the location of osteotomy, and to determine the following: size of osteotomy, angle of instrumentation, involvement of critical structures in flap reflection and involvement of vital structures during curettage. In addition, the participants' confidence in performing surgery was found to be significantly higher.

CONCLUSIONS

The availability of 3D printed models did not alter the participants' surgical approach but it significantly improved their confidence for endodontic microsurgery.

Accuracy of intraoral real-time navigation versus static, CAD/CAM-manufactured pilot drilling guides in dental implant surgery: an in vitro study

Background

Nowadays, 3D planning and static for dynamic aids play an increasing role in oral rehabilitation of the masticatory apparatus with dental implants. The aim of this study is to compare the accuracy of implant placement using a 3D-printed drilling guide and an intraoral real-time dynamic navigation system.

Methods

A total of 60 implants were placed on 12 partially edentulous lower jaw models. 30 were placed with pilot drilling guides, the other half with dynamic navigation (DENACAM^®). In addition, implant placement in interdental gaps and free-end situations were investigated. Accuracy was assessed by cone-beam computed tomography (CBCT).

Results

Both systems achieved clinically acceptable results, yet more accurate results regarding the offset of implant base and tip in several spatial dimensions were achieved using drilling guides (each p < 0.05). With regard to angulation, real-time navigation was more precise (p = 0.0016). Its inaccuracy was 3°; the template-guided systems was 4.6°. Median horizontal deviation was 0.52 mm at base and 0.75 mm at tip using DENACAM^®. When using the pilot drill guide, horizontal deviation was 0.34 mm in the median and at the tip by 0.59 mm. Regarding angulation, it was found that the closer the drill hole was to the system's marker, the better navigation performed. The template did not show this trend (p = 0.0043; and p = 0.0022).

Conclusion

Considering the limitations of an in vitro study, dynamic navigation can be used be a tool for reliable and accurate implantation. However, further clinical studies need to follow in order to provide an evidence-based recommendation for use in vivo.

Supplementary Information

The online version contains supplementary material available at 10.1186/s40729-022-00430-6.

Accuracy of the Surface Contour of Three-Dimensional-Printed Canine Pelvic Replicas

OBJECTIVE

The aim of this study was to determine the differences in surface contour between models of native pelvic bones and their corresponding three-dimensional (3D)-printed replicas.

STUDY DESIGN

Digital 3D models of five cadaveric hemipelves and five live dogs with contralateral pelvic fractures were generated based on computed tomographic images and 3D printed. The 3D-printed replicas underwent 3D scanning and digital 3D models of the replicas were created. The digital 3D model of each replica was superimposed onto the model of the native hemipelvis. Errors in the replicas were determined by comparing the distances of 120,000 corresponding surface points between models. The medial surface, lateral surface and dorsal surface of the acetabulum (DSA) of each hemipelvis were selected for further analysis. The root mean square error (RMSE) was compared between various selected areas using a one-way repeated measures analysis of variance, followed by a Bonferroni post-hoc test.

RESULTS

The RMSE of the hemipelvis was 0.25 ± 0.05 mm. The RMSE significantly decreased from the medial surface (0.28 ± 0.06mm), to the lateral surface (0.23 ± 0.06mm), to the DSA (0.04 ± 0.02mm) (p < 0.001).

CONCLUSION

The 3D-printed replicas were adequate in serving as a template for the pre-contouring of bone plates in fracture repair of pelvic fractures, particularly those that demand accurate reduction such as acetabular fractures.

Accuracy of additive manufacturing in stomatology

With the rapid development of the three-dimensional (3D) printing technology in recent decades, precise and personalized manufacturing has been achieved gradually, bringing benefit to biomedical application, especially stomatology clinical practice. So far, 3D printing has been widely applied to prosthodontics, orthodontics, and maxillofacial surgery procedures, realizing accurate, efficient operation processes and promising treatment outcomes. Although the printing accuracy has improved, further exploration is still needed. Herein, we summarized the various additive manufacturing techniques and their applications in dentistry while highlighting the importance of accuracy (precision and trueness).

Medical 3D Printing Dimensional Accuracy for Multi-pathological Anatomical Models 3D Printed Using Material Extrusion

Medical 3D printing of anatomical models is being increasingly applied in healthcare facilities. The accuracy of such 3D-printed anatomical models is an important aspect of their overall quality control. The purpose of this research was to test whether the accuracy of a variety of anatomical models 3D printed using Material Extrusion (MEX) lies within a reasonable tolerance level, defined as less than 1-mm dimensional error. Six medical models spanning across anatomical regions (musculoskeletal, neurological, abdominal, cardiovascular) and sizes (model volumes ranging from ~ 4 to 203 cc) were chosen for the primary study. Three measurement landing blocks were strategically designed within each of the six medical models to allow high-resolution caliper measurements. An 8-cc reference cube was printed as the 7th model in the primary study. In the secondary study, the effect of model rotation and scale was assessed using two of the models from the first study. All models were 3D printed using an Ultimaker 3 printer in triplicates. All absolute measurement errors were found to be less than 1 mm with a maximum error of 0.89 mm. The maximum relative error was 2.78%. The average absolute error was 0.26 mm, and the average relative error was 0.71% in the primary study, and the results were similar in the secondary study with an average absolute error of 0.30 mm and an average relative error of 0.60%. The relative errors demonstrated certain patterns in the data, which were explained based on the mechanics of MEX 3D printing. Results indicate that the MEX process, when carefully assessed on a case-by-case basis, could be suitable for the 3D printing of multi-pathological anatomical models for surgical planning if an accuracy level of 1 mm is deemed sufficient for the application.

Manufacturing Polymer Model of Anatomical Structures with Increased Accuracy Using CAx and AM Systems for Planning Orthopedic Procedures

Currently, medicine uses typical industrial structure techniques, including reverse engineering, data processing, 3D-CAD modeling, 3D printing, and coordinate measurement techniques. Taking this into account, one can notice the applications of procedures used in the aviation or automotive industries based on the structure of Industry 4.0 in the planning of operations and the production of medical models with high geometric accuracy. The procedure presented in the publication shortens the processing time of tomographic data and increases the reconstruction accuracy within the hip and knee joints. The procedure allows for the partial removal of metallic artifacts from the diagnostic image. Additionally, numerical models of anatomical structures, implants, and bone cement were developed in more detail by averaging the values of local segmentation thresholds. Before the model manufacturing process, additional tests of the PLA material were conducted in terms of its strength and thermal properties. Their goal was to select the appropriate type of PLA material for manufacturing models of anatomical structures. The numerical models were divided into parts before being manufactured using the Fused Filament Fabrication technique. The use of the modifier made it possible to change the density, type of filling, number of counters, and the type of supporting structure. These treatments allowed us to reduce costs and production time and increase the accuracy of the printout. The accuracy of the manufactured model geometry was verified using the MCA-II measuring arm with the MMDx100 laser head and surface roughness using a 3D Talyscan 150 profilometer. Using the procedure, a decrease in geometric deviations and amplitude parameters of the surface roughness were noticed. The models based on the presented approach allowed for detailed and meticulous treatment planning.

Dimensional variability characterization of additively manufactured lattice coupons

Background

Additive manufacturing (AM), commonly called 3D Printing (3DP), for medical devices is growing in popularity due to the technology’s ability to create complex geometries and patient-matched products. However, due to the process variabilities which can exist between 3DP systems, manufacturer workflows, and digital conversions, there may be variabilities among 3DP parts or between design files and final manufactured products. The overall goal of this project is to determine the dimensional variability of commercially obtained 3DP titanium lattice-containing test coupons and compare it to the original design files.

Methods

This manuscript outlines the procedure used to measure dimensional variability of 3D Printed lattice coupons and analyze the differences in external dimensions and pore area when using laser and electron beam fabricated samples. The key dimensions measured were the bulk length, width, and depth using calipers. Strut thickness and pore area were assessed for the lattice components using optical imaging and µCT.

Results

Results show a difference in dimensional measurement between printed parts and the computer-designed files for all groups analyzed including the internal lattice dimensions. Measurements of laser manufactured coupons varied from the nominal by less than 0.2 mm and results show averages greater than the nominal value for length, width, and depth dimensions. Measurements of Electron Beam Melting coupons varied between 0.4 mm-0.7 mm from the nominal value and showed average lengths below the nominal dimension while the width and depths were greater than the nominal values. The length dimensions of Laser Powder Bed Fusion samples appeared to be impacted by hot isostatic press more than the width and depth dimension. When lattice relative density was varied, there appeared to be little impact on the external dimensional variability for the as-printed state.

Conclusions

Based on these results, we can conclude that there are relevant variations between designed files and printed parts. However, we cannot currently state if these results are clinically relevant and further testing needs to be conducted to apply these results to real-world situations.

Comparison of blood pool and myocardial 3D printing in the diagnosis of types of congenital heart disease

The study aimed to evaluate the effectiveness of blood pool and myocardial models made by stereolithography in the diagnosis of different types of congenital heart disease (CHD). Two modeling methods were applied in the diagnosis of 8 cases, and two control groups consisting of experts and students diagnosed the cases using echocardiography with computed tomography, blood pool models, and myocardial models. The importance, suitability, and simulation degree of different models were analyzed. The average diagnostic rate before and after 3D printing was used was 88.75% and 95.9% (P = 0.001) in the expert group and 60% and 91.6% (P = 0.000) in the student group, respectively. 3D printing was considered to be more important for the diagnosis of complex CHDs (very important; average, 87.8%) than simple CHDs (very important; average, 30.8%) (P = 0.000). Myocardial models were considered most realistic regarding the structure of the heart (average, 92.5%). In cases of congenital corrected transposition of great arteries, Williams syndrome, coronary artery fistula, tetralogy of Fallot, patent ductus arteriosus, and coarctation of the aorta, blood pool models were considered more effective (average, 92.1%), while in cases of double outlet right ventricle and ventricular septal defect, myocardial models were considered optimal (average, 80%).

Additive Manufacturing in Orthopedics: A Review

Additive manufacturing is an advanced manufacturing manner that seems like the industrial revolution. It has the inborn benefit of producing complex formations, which are distinct from traditional machining technology. Its manufacturing strategy is flexible, including a wide range of materials, and its manufacturing cycle is short. Additive manufacturing techniques are progressively used in bone research and orthopedic operation as more innovative materials are developed. This Review lists the recent research results, analyzes the strengths and weaknesses of diverse three-dimensional printing strategies in orthopedics, and sums up the use of varying 3D printing strategies in surgical guides, surgical implants, surgical predictive models, and bone tissue engineering. Moreover, various postprocessing methods for additive manufacturing for orthopedics are described.

A Literature Review of Rapid Prototyping and Patient Specific Implants for the Treatment of Orbital Fractures

Post-traumatic reconstruction of the orbit can pose a challenge due to inherent intraoperative problems. Intra-orbital adipose tissue is difficult to manipulate and retract making visualization of the posterior orbital contents difficult. Rapid prototyping (RP) is a cost-effective method of anatomical model production allowing the surgeon to produce a patient specific implant (PSI) which can be pre-surgically adapted to the orbital defect with exact reconstruction. Intraoperative imaging allows immediate assessment of reconstruction at the time of surgery. Utilization and combination of both technologies improves accuracy of reconstruction with orbital implants and reduces cost, surgical time, and the rate of revision surgery.

Dimensional accuracy of 3D printing navigation templates of chemical-based sterilisation

3D printed navigational templates have facilitated the accurate treatment of orthopaedic patients. However, during practical operation, it is found that the location hole occasionally deviates from the ideal channel. As such, there will be a security risk in clinical applications. The purpose of this study was to evaluate the influence of chemical-based sterilisation methods on the dimensional accuracy of different materials and the influence of module parameters on the degree of deformation. We found that polylactic (PLA) modules sterilised with ethylene oxide (EO) would undergo micro-deformation, and these micro-deformation characteristics depend on the building direction, i.e., the module stretches in the Z direction and shrinks in the X and Y directions. Heat-resisting polylactide (HR-PLA) has the same melting temperature (T_m) as PLA, but its glass transition temperature (T_g) is greater than the EO sterilisation temperature, so there is no obvious deformation after EO sterilisation. The layer height of the module were inversely proportional to the degree of deformation in the same sterilisation method. The deformation time of the module is concentrated within 2 h after heating. The micro-deformation of the 3D printing module depends on its T_g, sterilisation temperature, and duration of the sterilisation cycle.

Procedure Increasing the Accuracy of Modelling and the Manufacturing of Surgical Templates with the Use of 3D Printing Techniques, Applied in Planning the Procedures of Reconstruction of the Mandible

The application of anatomical models and surgical templates in maxillofacial surgery allows, among other benefits, the increase of precision and the shortening of the operation time. Insufficiently precise anastomosis of the broken parts of the mandible may adversely affect the functioning of this organ. Applying the modern mechanical engineering methods, including computer-aided design methods (CAD), reverse engineering (RE), and rapid prototyping (RP), a procedure used to shorten the data processing time and increase the accuracy of modelling anatomical structures and the surgical templates with the use of 3D printing techniques was developed. The basis for developing and testing this procedure was the medical imaging data DICOM of patients treated at the Maxillofacial Surgery Clinic of the Fryderyk Chopin Provincial Clinical Hospital in Rzeszów. The patients were operated on because of malignant tumours of the floor of the oral cavity and the necrosis of the mandibular corpus, requiring an extensive resection of the soft tissues and resection of the mandible. Familiarity with and the implementation of the developed procedure allowed doctors to plan the operation precisely and prepare the surgical templates and tools in terms of the expected accuracy of the procedures. The models obtained based on this procedure shortened the operation time and increased the accuracy of performance, which accelerated the patient’s rehabilitation in the further course of events.

Effect of Printing Layer Thickness on the Trueness and Margin Quality of 3D-Printed Interim Dental Crowns

The information in the literature on the effect of printing layer thickness on interim 3D-printed crowns is limited. In the present study, the effect of layer thickness on the trueness and margin quality of 3D-printed composite resin crowns was investigated and compared with milled crowns. The crowns were printed in 3 different layer thicknesses (20, 50, and 100 μm) by using a hybrid resin based on acrylic esters with inorganic microfillers or milled from polymethylmethacrylate (PMMA) discs and digitized with an intraoral scanner (test scans). The compare tool of the 3D analysis software was used to superimpose the test scans and the computer-aided design file by using the manual alignment tool and to virtually separate the surfaces. Deviations at different surfaces on crowns were calculated by using root mean square (RMS). Margin quality of crowns was examined under a stereomicroscope and graded. The data were evaluated with one-way ANOVA and Tukey HSD tests. The layer thickness affected the trueness and margin quality of 3D-printed interim crowns. Milled crowns had higher trueness on intaglio and intaglio occlusal surfaces than 100 μm-layer thickness crowns. Milled crowns had the highest margin quality, while 20 μm and 100 μm layer thickness printed crowns had the lowest. The quality varied depending on the location of the margin.

Automated melt electrowritting platform with real-time process monitoring

Melt electrowriting (MEW) is an additive manufacturing (AM) technology with the ability to fabricate complex designs with high-resolution. The utility of MEW is studied in many fields including tissue engineering and soft robotics. However, current MEW hardware offers only basic functionality and is often designed and built in-house. This affects results replication across different MEW devices and slows down the technological advancement. To address these issues, we present an automated MEW platform with real-time process parameter monitoring and control. We validate the developed platform by demonstrating the ability to accurately print polymer structures and successfully measure and adjust parameters during the printing process. The platform enables the collection of large volumes of data that can be subsequently used for further analysis of the system. Ultimately, the concept will help MEW to become more accessible for both research laboratories and industry and allow advancing the technology by leveraging the process monitoring, control and data collection.

Formulation of a Ceramic Ink for 3D Inkjet Printing

Due to its multi-material capabilities, 3D inkjet printing allows for the fabrication of components with functional elements which may significantly reduce the production steps. The potential to print electronics requires jettable polymer-ceramic composites for thermal management. In this study, a respective material was formulated by functionalizing submicron alumina particles by 3-(trimethoxysilyl)propylmethacrylate (MPS) and suspending them in a mixture of the oligourethane Genomer 4247 with two acrylate functionalities and a volatile solvent. Ink jetting tests were performed, as well as thermal conductance and mechanical property measurements. The material met the strict requirements of the printing technology, showing viscosities of around 16 mPa·s as a liquid. After solidification, it exhibited a ceramic content of 50 vol%, with a thermal conductance of 1 W/(m·K). The resulting values reflect the physical possibilities within the frame of the allowed tolerances set by the production method.

A focused simulation-based optimization of print time and material usage with respect to orientation, layer height and support settings for multi-pathological anatomical models in inverted vat photopolymerization 3D printing

Background

3D printing of anatomical models requires multi-factorial decision making for optimal model manufacturing. Due to the complex nature of the printing process, there are frequently multiple potentialities based on the desired end goal. The task of identifying the most optimal combination of print control variables is inherently subjective and rests on sound operator intuition. This study investigates the effect of orientation, layer and support settings on print time and material usage. This study also presents a quantitative optimization framework to jointly optimize print time and material usage as a function of those settings for multi-pathological anatomical models.

Methods

Seven anatomical models representing different anatomical regions (cardiovascular, abdominal, neurological and maxillofacial) were selected for this study. A reference cube was also included in the simulations. Using PreForm print preparation software the print time and material usage was simulated for each model across 4 orientations, 2 layer heights, 2 support densities and 2 support tip sizes. A 90–10 weighted optimization was performed to identify the 5 most optimal treatment combinations that resulted in the lowest print time (90% weight) and material usage (10% weight) for each model.

Results

The 0.1 mm layer height was uniformly the most optimal setting across all models. Layer height had the largest effect on print time. Orientation had a complex effect on both print time and material usage in certain models. The support density and the support tip size settings were found to have a relatively minor effect on both print time and material usage. Hollow models had a larger support volume fraction compared to solid models.

Conclusions

The quantitative optimization framework identified the 5 most optimal treatment combinations for each model using a 90–10 weighting for print time and material usage. The presented optimization framework could be adapted based on the individual circumstance of each 3D printing lab and/or to potentially incorporate additional response variables of interest.

The State of the Art of Material Jetting-A Critical Review

Material jetting (MJ) technology is an additive manufacturing method that selectively cures liquid photopolymer to build functional parts. The use of MJ technology has increased in popularity and been adapted by different industries, ranging from biomedicine and dentistry to manufacturing and aviation, thanks to its advantages in printing parts with high dimensional accuracy and low surface roughness. To better understand the MJ technology, it is essential to address the capabilities, applications and the usage areas of MJ. Additionally, the comparison of MJ with alternative methods and its limitations need to be explained. Moreover, the parameters influencing the dimensional accuracy and mechanical properties of MJ printed parts should be stated. This paper aims to review these critical aspects of MJ manufacturing altogether to provide an overall insight into the state of the art of MJ.

Estimating the Accuracy of Mandible Anatomical Models Manufactured Using Material Extrusion Methods

The development of new solutions in craniofacial surgery brings the need to increase the accuracy of 3D printing models. The accuracy of the manufactured models is most often verified using optical coordinate measuring systems. However, so far, no decision has been taken regarding which type of system would allow for a reliable estimation of the geometrical accuracy of the anatomical models. Three types of optical measurement systems (Atos III Triple Scan, articulated arm (MCA-II) with a laser head (MMD × 100), and Benchtop CT160Xi) were used to verify the accuracy of 12 polymer anatomical models of the left side of the mandible. The models were manufactured using fused deposition modeling (FDM), melted and extruded modeling (MEM), and fused filament fabrication (FFF) techniques. The obtained results indicate that the Atos III Triple Scan allows for the most accurate estimation of errors in model manufacturing. Using the FDM technique obtained the best accuracy in models manufactured (0.008 ± 0.118 mm for ABS0-M30 and 0.016 ± 0.178 mm for PC-10 material). A very similar value of the standard deviation of PLA and PET material was observed (about 0.180 mm). The worst results were observed in the MEM technique (0.012 mm ± 0.308 mm). The knowledge regarding the precisely evaluated errors in manufactured models within the mandibular area will help in the controlled preparation of templates regarding the expected accuracy of surgical operations.

The accuracy of clinical 3D printing in reconstructive surgery: literature review and in vivo validation study

A growing number of studies demonstrate the benefits of 3D printing in improving surgical efficiency and subsequently clinical outcomes. However, the number of studies evaluating the accuracy of 3D printing techniques remains scarce. All publications appraising the accuracy of 3D printing between 1950 and 2018 were reviewed using well-established databases, including PubMed, Medline, Web of Science and Embase. An in vivo validation study of our 3D printing technique was undertaken using unprocessed chicken radius bones (Gallus gallus domesticus). Calculating its maximum length, we compared the measurements from computed tomography (CT) scans (CT group), image segmentation (SEG group) and 3D-printed (3DP) models (3DP group). Twenty-eight comparison studies in 19 papers have been identified. Published mean error of CT-based 3D printing techniques were 0.46 mm (1.06%) in stereolithography, 1.05 mm (1.78%) in binder jet technology, 0.72 mm (0.82%) in PolyJet technique, 0.20 mm (0.95%) in fused filament fabrication (FFF) and 0.72 mm (1.25%) in selective laser sintering (SLS). In the current in vivo validation study, mean errors were 0.34 mm (0.86%) in CT group, 1.02 mm (2.51%) in SEG group and 1.16 mm (2.84%) in 3DP group. Our Peninsula 3D printing technique using a FFF 3D printer thus produced accuracy similar to the published studies (1.16 mm, 2.84%). There was a statistically significant difference (P<10-4) between the CT group and the latter SEG and 3DP groups indicating that most of the error is introduced during image segmentation stage.

A method for finding high accuracy surface zones on 3D printed bone models

The use of three-dimensional (3D) printing for surgical applications is steadily increasing. Errors in the printed models can lead to complications, especially when the model is used for surgery planning or diagnostics. In patient care, the validation of printed models should therefore be performed routinely. However, there currently is no standard method to determine whether the printed model meets the necessary quality requirements. In this work, we present a method that not only finds surface deviations of a printed model, but also shows high accuracy zones of a potentially corrupted model, that are safe to be used for surgery planning. Our method was tested on printed patient bone models with acetabular fractures and was compared to two common methods in orthopedics, simple landmark registration as well as landmark plus subsequent iterative closest point registration. In order to find suitable parameters and to evaluate the performance of our method, 15 digital acetabular bone models were artificially deformed, imitating four typical 3D printing errors. A sensitivity of over 95% and a specificity of over 99% was observed in finding these surface deformations. Then, the method was applied to 32 printed models that had been re-digitized using a computed tomography scanner. It was found that only 25% of these printed models were free of significant deformations. However, focussing on two common implant locations, our method revealed that 72% of the models were within the acceptable error tolerance. In comparison, simple landmark registration resulted in a 9% acceptance rate and landmark registration followed by iterative closest point registration resulted in a 41% acceptance rate. This outcome shows that our method, named Similarity Subgroups Registration, allows clinicians to safely use partially corrupted 3D printed models for surgery planning. This improves efficiency and reduces time to treatment by avoiding reprints. The similarity subgroups registration is applicable in further clinical domains as well as non-medical applications that share the requirement of local high accuracy zones on the surface of a 3D model.

Main 3D Manufacturing Techniques for Customized Bone Substitutes. A Systematic Review

Clinicians should be aware of the main methods and materials to face the challenge of bone shortage by manufacturing customized grafts, in order to repair defects. This study aims to carry out a bibliographic review of the existing methods to manufacture customized bone scaffolds through 3D technology and to identify their current situation based on the published papers. A literature search was carried out using "3D scaffold", "bone regeneration", "robocasting" and "3D printing" as descriptors. This search strategy was performed on PubMed (MEDLINE), Scopus and Cochrane Library, but also by hand search in relevant journals and throughout the selected papers. All the papers focusing on techniques for manufacturing customized bone scaffolds were reviewed. The 62 articles identified described 14 techniques (4 subtraction + 10 addition techniques). Scaffold fabrication techniques can be also be classified according to the time at which they are developed, into Conventional techniques and Solid Freeform Fabrication techniques. The conventional techniques are unable to control the architecture of the pore and the pore interconnection. However, current Solid Freeform Fabrication techniques allow individualizing and generating complex geometries of porosity. To conclude, currently SLA (Stereolithography), Robocasting and FDM (Fused deposition modeling) are promising options in customized bone regeneration.

Polymer 3D Printing Review: Materials, Process, and Design Strategies for Medical Applications

Polymer 3D printing is an emerging technology with recent research translating towards increased use in industry, particularly in medical fields. Polymer printing is advantageous because it enables printing low-cost functional parts with diverse properties and capabilities. Here, we provide a review of recent research advances for polymer 3D printing by investigating research related to materials, processes, and design strategies for medical applications. Research in materials has led to the development of polymers with advantageous characteristics for mechanics and biocompatibility, with tuning of mechanical properties achieved by altering printing process parameters. Suitable polymer printing processes include extrusion, resin, and powder 3D printing, which enable directed material deposition for the design of advantageous and customized architectures. Design strategies, such as hierarchical distribution of materials, enable balancing of conflicting properties, such as mechanical and biological needs for tissue scaffolds. Further medical applications reviewed include safety equipment, dental implants, and drug delivery systems, with findings suggesting a need for improved design methods to navigate the complex decision space enabled by 3D printing. Further research across these areas will lead to continued improvement of 3D-printed design performance that is essential for advancing frontiers across engineering and medicine.

3D Printed Models-A Useful Tool in Endovascular Treatment of Intracranial Aneurysms

Many developments were made in the area of endovascular treatment of intracranial aneurysms, but this procedure also requires a good assessment of vascular anatomy prior to intervention. Seventy-six cases with brain aneurysms were selected and 1:1 scale 3D printed models were created. We asked three interventional neurosurgeons with different degrees of experience (ten years, four years, and a fourth-year resident) to review the cases using CTA (computed tomography angiogram) with MPR (multiplanar reconstructions) and VRT (volume rendering technique) and make a decision: coil embolization or stent-assisted coil embolization. After we provided them with the 3D printed models, they were asked to review their treatment plan. Statistical analysis was performed and the endovascular approach changed in 11.84% of cases for ten-year experienced neurosurgeons, 13.15% for four years experienced neurosurgeon, and 21.05% for residents. The interobserver agreement was very good between the ten years experienced interventionist and four years experienced interventionist when they analyzed the data set that included the 3D printed model. The agreement was higher between all physicians after they examined the printed model. 3D patient-specific printed models may be useful in choosing between two different endovascular techniques and also help the residents to better understand the vascular anatomy and the overall procedure.

Accuracy of Three-Dimensional (3D) Printed Dental Digital Models Generated with Three Types of Resin Polymers by Extra-Oral Optical Scanning

Digital impression devices are used alternatively to conventional impression techniques and materials. The aim of this study was to evaluate the precision of extraoral digitalization of three types of photosensitive resin polymers used for 3D printing with the aid of a digital extraoral optical scanner. The alignment of the scans was performed by a standard best-fit alignment. Trueness and precision were used to evaluate the models. The trueness was evaluated by using bias as a measure and the standard deviation was used to evaluate the precision. After assessing the normality of the distributions, an independent Kruskal–Wallis test was used to compare the trueness and precision across the material groups. The Mann–Whitney test was used as a post-hoc test for significant differences. The result of the analysis showed significant differences (U = 66, z = −2.337, p = 0.019) in trueness of mesiodistal distances. Upon visual inspection of the models, defects were noticed on two out of nine of the models printed with a photosensitive polymer. The defects were presented as cavities caused by air bubbles and were also reflected in the scans. Mean precision did not vary too much between these three photosensitive polymer resins, therefore, the selection of 3D printing materials should be based on the trueness and the required precision of the clinical purpose of the model.

Comparison of additive manufactured models of the mandible in accuracy and quality using six different 3D printing systems

The aim of this study was to analyze and compare the accuracy and quality of six 3D printing systems available on the market. Data acquisition was performed with 12 scans of human mandibles using an industrial 3D scanner and saved in STL format. These STL files were printed using six different printing systems. Previously defined distances were measured with a sliding caliper on the 72 printed mandibles. The printed models were then scanned once again. Measurements of volumes and surfaces for the STL files and the printed models were compared. Accuracy and quality were evaluated using industrial software. An analysis of the punctual aberration between the template and the printed model, based on a heat map, was also carried out. Secondary factors, such as costs, production times and expendable materials, were also examined. All printing systems performed well in terms of accuracy and quality for clinical usage. The Formiga P110 and the Form 2 showed the best results for volume, with average aberrations of 0.13 ± 0.23 cm³ and 0.12 ± 0.17 cm³, respectively. Similar results were achieved for the heat map aberration, with values of 0.008 ± 0.11 mm (Formiga P110) and 0.004 ± 0.16 mm (Form 2). Both printers showed no significant difference from the optimal neutral line (Formiga P110, p = 0.15; Form 2, p = 0.60). The cheapest models were produced by the Ultimaker 2+, with an average of 5€ per model, making such desktop printers affordable for rapid prototyping. Meanwhile, advanced printing systems with sterilizable and biocompatible printing materials, such as the Formiga P110 and the Form 2, fulfill the high expectations for maxillofacial surgery.

A systematic evaluation of medical 3D printing accuracy of multi-pathological anatomical models for surgical planning manufactured in elastic and rigid material using desktop inverted vat photopolymerization

PURPOSE

The dimensional accuracy of three-dimensional (3D) printed anatomical models is essential to correctly understand spatial relationships and enable safe presurgical planning. Most recent accuracy studies focused on 3D printing of a single pathology for surgical planning. This study evaluated the accuracy of medical models across multiple pathologies, using desktop inverted vat photopolymerization (VP) to 3D print anatomic models using both rigid and elastic materials.

METHODS

In the primary study, we 3D printed seven models (six anatomic models and one reference cube) with volumes ranging from ~2 to ~209 cc. The anatomic models spanned multiple pathologies (neurological, cardiovascular, abdominal, musculoskeletal). Two solid measurement landing blocks were strategically created around the pathology to allow high-resolution measurement using a digital micrometer and/or caliper. The physical measurements were compared to the designed dimensions, and further analysis was conducted regarding the observed patterns in accuracy. All of the models were printed in three resins: Elastic, Clear, and Grey Pro in the primary experiments. A full factorial block experimental design was employed and a total of 42 models were 3D printed in 21 print runs. In the secondary study, we 3D printed two of the anatomic models in triplicates selected from the previous six to evaluate the effect of 0.1 mm vs 0.05 mm layer height on the accuracy.

RESULTS

In the primary experiment, all dimensional errors were less than 1 mm. The average dimensional error across the 42 models was 0.238  ±  0.219 mm and the relative error was 1.10  ±  1.13%. Results from the secondary experiments were similar with an average dimensional error of 0.252  ±  0.213 mm and relative error of 1.52%  ±  1.28% across 18 models. There was a statistically significant difference in the relative errors between the Elastic resin and Clear resin groups. We explained this difference by evaluating inverted VP 3D printing peel forces. There was a significant difference between the Solid and Hollow group of models. There was a significant difference between measurement landing blocks oriented Horizontally and Vertically. In the secondary experiments, there was no difference in accuracy between the 0.10 and 0.05 mm layer heights.

CONCLUSIONS

The maximum measured error was less than 1 mm across all models, and the mean error was less than 0.26mm. Therefore, inverted VP 3D printing technology is suitable for medical 3D printing if 1 mm is considered the cutoff for clinical use cases. The 0.1 mm layer height is suitable for 3D printing accurate anatomical models for presurgical planning in a majority of cases. Elastic models, models oriented horizontally, and models that are hollow tend to have relatively higher deviation as seen from experimental results and mathematical model predictions. While clinically insignificant using a 1 mm cutoff, further research is needed to better understand the complex physical interactions in VP 3D printing which influence model accuracy.

Dimensional Accuracy of Dental Models for Three-Unit Prostheses Fabricated by Various 3D Printing Technologies

Previous studies on accuracy of three-dimensional (3D) printed model focused on full arch measurements at few points. The aim of this study was to examine the dimensional accuracy of 3D-printed models which were teeth-prepped for three-unit fixed prostheses, especially at margin and proximal contact areas. The prepped dental model was scanned with a desktop scanner. Using this reference file, test models were fabricated by digital light processing (DLP), Multi-Jet printing (MJP), and stereo-lithography apparatus (SLA) techniques. We calculated the accuracy (trueness and precision) of 3D-printed models on 3D planes, and deviations of each measured points at buccolingual and mesiodistal planes. We also analyzed the surface roughness of resin printed models. For overall 3D analysis, MJP showed significantly higher accuracy (trueness) than DLP and SLA techniques; however, there was not any statistically significant difference on precision. For deviations on margins of molar tooth and distance to proximal contact, MJP showed significantly accurate results; however, for a premolar tooth, there was no significant difference between the groups. 3D color maps of printed models showed contraction buccolingually, and surface roughness of the models fabricated by MJP technique was observed as the lowest. The accuracy of the 3D-printed resin models by DLP, MJP, and SLA techniques showed a clinically acceptable range to use as a working model for manufacturing dental prostheses

Three-dimensional design of a geometric model for an ocular prosthesis in ex vivo anophthalmic socket models

PURPOSE

Fitting a customized ocular prosthesis for anophthalmic patients entails an artisanal labour-exhausting process and is standardly based on impression moulding of the socket, which may be anatomically inaccurate. The objective of the study was to design an impression-free socket mould with three-dimensional (3D) technology.

METHODS

The ex vivo anophthalmic socket models included one silicone, one fresh pig cadaver head and three fresh-frozen human cadaver heads. After intra-socket application with iodine substance, five observers obtained eighteen low-dose cone beam computed tomography (CBCT) scans and one observer one high-dose CBCT scan of each model. The observers designed non-impression 3D moulds of the socket with 3D software. For the human cadaver sockets 3D geometric models of the ocular prosthesis were rendered from the 3D mould of the socket and the mirrored cornea of the contralateral eye.

RESULTS

The posterior surface of the 3D mould was highly accurate, with a mean absolute deviation of 0.28 mm, 0.53 mm, 0.37 mm and mean upper deviation of 0.53 mm, 0.86 mm, 1.17 mm, respectively, for the phantom, pig and human model. The intra- and interobserver repeatability and reproducibility of the 3D moulds and designs was good (<0.35 mm). The largest variation in the 3D geometric model was found at the junction of the 3D mould and mirrored cornea.

CONCLUSION

3D design of an impression-free geometric model for an ocular prosthesis with low-dose CBCT is highly accurate in ex vivo anophthalmic socket models. This novel method is a critical step towards the manufacturing of 3D printed ocular prostheses and requires validation in anophthalmic patients.

Additive Manufacturing Processes in Medical Applications

Additive manufacturing (AM, 3D printing) is used in many fields and different industries. In the medical and dental field, every patient is unique and, therefore, AM has significant potential in personalized and customized solutions. This review explores what additive manufacturing processes and materials are utilized in medical and dental applications, especially focusing on processes that are less commonly used. The processes are categorized in ISO/ASTM process classes: powder bed fusion, material extrusion, VAT photopolymerization, material jetting, binder jetting, sheet lamination and directed energy deposition combined with classification of medical applications of AM. Based on the findings, it seems that directed energy deposition is utilized rarely only in implants and sheet lamination rarely for medical models or phantoms. Powder bed fusion, material extrusion and VAT photopolymerization are utilized in all categories. Material jetting is not used for implants and biomanufacturing, and binder jetting is not utilized for tools, instruments and parts for medical devices. The most common materials are thermoplastics, photopolymers and metals such as titanium alloys. If standard terminology of AM would be followed, this would allow a more systematic review of the utilization of different AM processes. Current development in binder jetting would allow more possibilities in the future.

Cost Modeling and Evaluation of Direct Metal Laser Sintering with Integrated Dynamic Process Planning

Additive manufacturing technologies have been adopted in a wide range of industries such as automotive, aerospace, and consumer products. Currently, additive manufacturing is mainly used for small-scale, low volume productions due to its limitations such as high unit cost. To enhance the scalability of additive manufacturing, it is critical to evaluate and preferably reduce the cost of adopting additive manufacturing for production. The current literature on additive manufacturing cost mainly adopts empirical approaches and does not sufficiently explore the cost-saving potentials enabled by leveraging different process planning algorithms. In this article, a mathematical cost model is established to quantify the different cost components in the direct metal laser sintering process, and it is applicable for evaluating the cost performance when adopting dynamic process planning with different layer-wise process parameters. The case study results indicate that 12.73% of the total production cost could be potentially reduced when applying the proposed dynamic process planning algorithm based on the complexity level of geometries. In addition, the sensitivity analysis results suggest that the raw material price and the overhead cost are the two key cost drivers in the current additive manufacturing market.

Evaluation of the accuracy of digital and 3D-printed casts compared with conventional stone casts

STATEMENT OF PROBLEM

Digital scans present an efficient substitute for traditional dental impressions, although physical casts are still needed for some procedures, leading to the use of 3D printing in fixed prosthodontics. However, studies comparing the accuracy of 3D-printed dental casts with digital and conventional casts are sparse.

PURPOSE

The purpose of this in vitro study was to compare the accuracy of casts produced from 2 different intraoral scans using a stereolithographic (SLA) 3D- printing technique, their digital versions, and conventional stone casts with a reference cast and with each other.

MATERIAL AND METHODS

A reference cast was scanned by using 2 intraoral scanners, the TRIOS 3shape and the Dental Wings, producing 2 digital scans. SLA was used to print dental casts from the digital scans, and polyether impressions were poured in dental stone to produce conventional stone casts. Measurements of the 4 types of casts (TRIOS 3shape digital, Dental Wings digital, TRIOS 3shape printed, and Dental Wings-printed casts) were compared with the reference casts. Measurements of maxillary and mandibular canines, second premolars, and second molars included incisocervical or occlusocervical (crown height) and mesiodistal (crown width). Arch measurements included intercanine and intermolar widths. Geomagic imaging software was used to measure the digital casts. ANOVA was used to assess differences among groups in errors relative to the reference cast (α=.05).

RESULTS

In occlusocervical and mesiodistal, the errors of digital Dental Wings were significantly greater than the errors of the other 4 groups. For intercanine and intermolar widths, digital TRIOS 3shape and digital Dental Wings had significantly greater errors (mean=0.11 and 0.15 mm in intercanine width and 0.14 and 0.18 mm in intermolar width) than their printed counterparts and the conventional casts (means=0.02, 0.06, and 0.01 mm in intercanine width and 0.02, 0.04, and 0.01 mm in intermolar width). The digital Dental Wings cast had significantly greater errors than those of the other groups in all measurements. All errors were within the clinically acceptable level (<0.5 mm).

CONCLUSIONS

3D-printed casts had the lowest error rate relative to the reference cast and were similar to those of conventional stone casts. Digital casts had the greatest errors.

Guided Endodontics for Managing Severely Calcified Canals

Endodontic treatment of teeth with pulp canal obliteration presents a challenge given the high likelihood of procedural errors and complications during treatment. These drawbacks can be avoided by using a personalized 3-dimensional (3D) guide designed by overlaying a cone-beam computed tomographic scan with an intraoral scan of the patient. This 3D guide enables the clinician to obtain a straight access to the obliterated root canal.This article described guided endodontics in managing 7 severely obliterated teeth using both virtually designed 3D guides and a customized 1-mm-diameter cylindrical bur. This treatment approach was demonstrated to be safe and fast and can be considered as a predictable technique for the location of calcified canals, thus minimizing complications.

3D Printed Biomimetic Rabbit Airway Simulation Model for Nasotracheal Intubation Training

Rabbit inhalation anesthesia by endotracheal intubation involves a higher risk among small animals owing to several anatomical and physiological features, which is pathognomonic to this species of lagomorphs. Rabbit-specific airway devices have been designed to prevent misguided intubation attempts. However, it is believed that expert anesthetic training could be a boon in limiting the aftermaths of this procedure. Our research is aimed to develop a novel biomimetic 3D printed rabbit airway model with representative biomechanical material behavior and radiodensity. Imaging data were collected for two sacrificed rabbit heads using micro-computed tomography (μCT) and micro-magnetic resonance imaging for the first head and cone beam computed tomography (CBCT) for the second head. Imaging-based life-size musculoskeletal airway models were printed using polyjet technology with a combination of hard and soft materials in replicates of three. The models were evaluated quantitatively for dimensional accuracy and radiodensity and qualitatively using digital microscopy and endoscopy for technical, tactic, and visual realism. The results displayed that simulation models printed with polyjet technology have an overall surface representation of 93% for μCT-based images and 97% for CBCT-based images within a range of 0.0-2.5 mm, with μCT showing a more detailed reproduction of the nasotracheal anatomy. Dimensional discrepancies can be caused due to inadequate support material removal and due to the limited reconstruction of microstructures from the imaging on the 3D printed model. The model showed a significant difference in radiodensities in hard and soft tissue regions. Endoscopic evaluation provided good visual and tactile feedback, comparable to the real animal. Overall, the model, being a practical low-cost simulator, comprehensively accelerates the learning curve of veterinary nasotracheal intubation and paves the way for 3D simulation-based image-guided interventional procedures.