The Barrow Biomimetic Spine: Comparative Testing of a 3D-Printed L4-L5 Schwab Grade 2 Osteotomy Model to a Cadaveric Model

Expanding Clinician Access to High-Quality, Low-Cost Biomechanical Research: A Technical Report on the Carolina Neurosurgery and Spine Biomechanics Laboratory

Spine biomechanical research helps us better understand the spine in physiologic and pathologic states and gives us a mechanism by which to evaluate surgical interventions, generate and evaluate models of spine pathologies, and develop novel, data-driven surgical strategies and devices. Access to a biomechanical testing laboratory is therefore potentially invaluable to those who specialize in treating spine pathologies. A number of barriers to access have precluded many clinicians from pursuing their biomechanical research interests, foremost among these is cost. The Carolina Neurosurgery and Spine Biomechanics Research Laboratory (CNSBL) was developed as a model of a low-cost, easy-to-access laboratory capable of generating high-quality data in tests of axial load, tension, torque, displacement, and pathological model testing. Our experience in developing this laboratory suggests that a large number of basic biomechanical research inquiries can be studied in a laboratory composed of less than $7500 USD of hardware. We hope that this model serves as a roadmap for any like-minded practitioners seeking broader access to biomechanical testing facilities.

Utility of a Novel Biomimetic Spine Model in Surgical Education: Case Series of Three Cervicothoracic Kyphotic Deformities

STUDY DESIGN

Evaluation of new technology.

OBJECTIVES

To evaluate the utility of a novel biomimetic spine model as a surgical planning and education resource in the treatment of cervical spine deformities (CSD).

METHODS

Three patients with CSD were identified and synthetic spine models were manufactured to match the anatomical and biomechanical properties of each patient. Each model underwent 3 phases of surgical correction: maximum correction with no osteotomies performed, with posterior column osteotomies (PCOs) only, and with PCOs and a 3-column osteotomy (3CO). Lateral fluoroscopic films were obtained after each phase of correction for measurement of cervical lordosis. Surgeons were surveyed to obtain subjective feedback on the perceived model utility.

RESULTS

Each model began with a kyphotic deformity that was mobile, rigid, or fixed. The mobile model achieved successive lordotic correction with each phase of correction. The rigid and fixed models achieved much less correction with no osteotomies and PCOs only, and the majority of correction with 3COs. Each model predicted with varying, but overall high, accuracy the amount of correction achieved in each patient. The surgeons felt the model had very high utility as a surgical education platform.

CONCLUSIONS

The models appeared to accurately replicate the gross anatomy and biomechanical performance of the patients' spines. This high fidelity to the individual patient's anatomy, bone quality, and segmental mobility resulted in a custom model that provides an invaluable learning platform for surgical education. These results suggest the models may have utility in surgical planning, but further studies are needed.

Range of Motion Testing of a Novel 3D-Printed Synthetic Spine Model

STUDY DESIGN

Biomechanical model study.

OBJECTIVE

The Barrow Biomimetic Spine (BBS) project is a resident-driven effort to manufacture a synthetic spine model with high biomechanical fidelity to human tissue. The purpose of this study was to investigate the performance of the current generation of BBS models on biomechanical testing of range of motion (ROM) and axial compression and to compare the performance of these models to historical cadaveric data acquired using the same testing protocol.

METHODS

Six synthetic spine models comprising L3-5 segments were manufactured with variable soft-tissue densities and print orientations. Models underwent torque loading to a maximum of 7.5 N m. Torques were applied to the models in flexion-extension, lateral bending, axial rotation, and axial compression. Results were compared with historic cadaveric control data.

RESULTS

Each model demonstrated steadily decreasing ROM on flexion-extension testing with increasing density of the intervertebral discs and surrounding ligamentous structures. Vertically printed models demonstrated markedly less ROM than equivalent models printed horizontally at both L3-4 (5.0° vs 14.0°) and L4-5 (3.9° vs 15.2°). Models D and E demonstrated ROM values that bracketed the cadaveric controls at equivalent torque loads (7.5 N m).

CONCLUSIONS

This study identified relevant variables that affect synthetic spine model ROM and compressibility, confirmed that the models perform predictably with changes in these print variables, and identified a set of model parameters that result in a synthetic model with overall ROM that approximates that of a cadaveric model. Future studies can be undertaken to refine model performance and determine intermodel variability.

Investigation and Feasibility of Combined 3D Printed Thermoplastic Filament and Polymeric Foam to Simulate the Cortiocancellous Interface of Human Vertebrae

Disorders of the spine are among the most common indications for neurosurgical and orthopedic surgical interventions. Spinal fixation in the form of pedicle screw placement is a common form of instrumentation method in the lower cervical, thoracic, and lumbar spine. A vital principle to understand for the safe and accurate placement of pedicle screws is the palpable difference between the cortical and cancellous bone, both of which have different material properties and compositions. Probing and palpation of the hard cortical bone, also known as the “ventral lamina”, covering the neural elements of the spinal canal during screw placement provides manual feedback to the surgeon, indicating an impending breach if continued directional force is applied. Generally, this practice is learned at the expense of patients in live operating room scenarios. Currently, there is a paucity of human vertebra simulation designs that have been validated based on the in vivo ultrastructure and physical properties of human cortical and cancellous bone. In this study, we examined the feasibility of combining three-dimensionally printed thermoplastic polymers with polymeric foam to replicate both the vertebral corticocancellous interface and surface anatomy for procedural education.

The Barrow Biomimetic Spine: Face, Content, and Construct Validity of a 3D-Printed Spine Model for Freehand and Minimally Invasive Pedicle Screw Insertion

STUDY DESIGN

Description and evaluation of a novel surgical training platform.

OBJECTIVES

The purpose of this study was to investigate the face, content, and construct validity of 5 novel surgical training models that simulate freehand and percutaneous (minimally invasive surgery [MIS]) pedicle screw placement.

METHODS

Five spine models were developed by residents: 3 for freehand pedicle screw training (models A-C) and 2 for MIS pedicle screw training (models D and E). Attending spine surgeons evaluated each model and, using a 20-point Likert-type scale, answered survey questions on model face, content, and construct validity. Scores were statistically evaluated and compared using means, standard deviations, and analysis of variance between models and between surgeons.

RESULTS

Among the freehand models, model C demonstrated the highest overall validity, with mean face (15.67 ± 5.49), content (19.17 ± 0.59), and construct (18.83 ± 0.24) validity all measuring higher than the other freehand models. For the MIS models, model D had the highest validity scores (face, content, and construct validity of 11.67 ± 3.77, 18.17 ± 2.04, and 17.00 ± 3.46, respectively). The 3 freehand models differed significantly in content validity scores (P = .002) as did the 2 MIS models (P < .001). The testing surgeons' overall validity scores were significantly different for models A (P = .005) and E (P < .001).

CONCLUSIONS

A 3-dimensional-printed spine model with incorporated bone bleeding and silicone rubber soft tissue was scored as having very high content and construct validity for simulating freehand pedicle screw insertion. These data has informed the further development of several surgical training models that hold great potential as educational adjuncts in surgical training programs.

Development and first clinical use of a novel anatomical and biomechanical testing platform for scoliosis

BACKGROUND

Previous studies have demonstrated that, by using various three-dimensional (3D) printing technologies, synthetic spine models can be manufactured to mimic a human spine in its gross and radiographic anatomy and the biomechanical performance of bony and ligamentous tissue. These manufacturing processes have not, however, been used in combination to create a long-segment, biomimetic model of a patient with scoliosis. The purpose of this study was to describe the development of a biomimetic scoliosis model and early clinical experience using this model as a surgical planning and education platform.

METHODS

Synthetic spine models were printed to mimic the anatomy and biomechanical performance of 2 adult patients with scoliosis. Preoperatively, the models were surgically corrected by the attending surgeon of each patient. Patients then underwent surgical correction of their spinal deformities. Correction of the models was compared to the surgical correction in the patients.

RESULTS

Patient 1 had a preoperative coronal Cobb angle of 40° from L1 to S1, as did the patient's synthetic spine model. The patient's spine model was corrected to 17.6°, and the patient achieved a correction of 17.3°. Patient 2 had a preoperative mid-thoracic Cobb angle of 88° and an upper thoracic Cobb angle of 43°. Preoperatively, the patient's spine model was corrected to 19.5° and 9.2° for the mid-thoracic and upper thoracic curves, respectively. Immediately after surgery, the patient's mid-thoracic and upper thoracic Cobb angles measured 18.7° and 9.5°, respectively. In both cases, the use of the spine models preoperatively changed the attending surgeon's operative plan.

CONCLUSIONS

A novel synthetic spine model for corrective scoliosis procedures is presented, along with early clinical experience using this model as a surgical planning platform. This model has tremendous potential not only as a surgical planning platform but also as an adjunct to patient consent, surgical education, and biomechanical research.

A Feasibility Study for the Production of Three-dimensional-printed Spine Models Using Simultaneously Extruded Thermoplastic Polymers

Background Medical simulation is an emerging field for resident training. Three-dimensional printing has accelerated the development of models for spine surgical simulation. Previous models have utilized augmented infill ratios to simulate the density difference between cortical and cancellous bone; however, this does not fully account for differences in the material properties of these components of human vertebrae. In order to replicate the differences in both density and material characteristics for realistic spinal simulation, we created a three-dimensional model composed of multiple thermoplastic polymers. Materials and methods Three lumbar vertebrae and 20 C2 vertebrae models using an experimental dual material fabrication method were printed on an Ultimaker S5 3D printer. Assessment of model integrity during instrumentation as well as user tactile feedback were points of interest to determine prototype viability for educational and biomechanical use. The experimental cohort was compared with a control cohort consisting of a single material print, resin print, and polyurethane mold. Results Based on tactile feedback, the experimental dual material print (polylactic acid [PLA]/polyvinyl alcohol [PVA]) more accurately represented the sensation of in vivo instrumentation during pedicle probing, pedicle tapping, and screw placement. There were no instrumentation or material failures in the PLA/PVA experimental model cohort. Conclusions This feasibility study indicates that multiple material printing using PLA and PVA is a viable method to replicate the cortico-cancellous interface in vertebral models. This concept and design using our unique infill algorithm have not been yet reported in the medical literature. Further educational and biomechanical testing on our design is currently underway to establish this printing method as a new standard for spinal biomimetic modeling.

The Barrow Biomimetic Spine: effect of a 3-dimensional-printed spinal osteotomy model on performance of spinal osteotomies by medical students and interns

Background

The Schwab osteotomy grading scale-a unified osteotomy classification system created in 2014 by Schwab et al.-is one of many concepts in spine surgery that require detailed knowledge of 3-dimensional (3D) anatomy. 3D-printed spine models have demonstrated increasing utility in spine surgery as they more quickly communicate information on complex 3D anatomical relationships than planar imaging or 2-dimensional images. The purpose of this study was to evaluate the utility of a custom, 3D-printed spine model to help surgical trainees understand and perform the Schwab osteotomy grading scale.

Methods

Eight participants were randomized into 2 groups: group 1 received written instructional materials about the Schwab osteotomy grading scale, whereas group 2 received both written materials and a 3D-printed model of the spine with osteotomy regions demarcated. All participants were administered written and practical examinations.

Results

The group randomized to receive the 3D-printed model performed significantly better on both the written assessment (mean score, 7.75±0.50 vs. 5.75±0.50, P=0.023) and the practical examination (mean score, 1.75±0.32 vs. 1.08±0.09, P=0.025) than the group that received only written instructions.

Conclusions

Our results support the conclusion that this 3D-printed spine model is an effective adjunct to help early surgical trainees understand the Schwab osteotomy grading scale. Participants who received the model in addition to the source manuscript demonstrated improved theoretical knowledge and better performance on practical tests of complex spinal osteotomies. Similar models are likely to have utility in surgical training programs and as patient education models.