Biomechanical Testing of a 3D-printed L5 Vertebral Body 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.

Orientation Planning in the Fused Deposition Modeling 3D Printing of Anatomical Spine Models

Three‐dimensional (3D) printing has revolutionized medical training and patient care. Clinically it is used for patient‐specific anatomical modeling with respect to surgical procedures. 3D printing is heavily implemented for simulation to provide a useful tool for anatomical knowledge and surgical techniques. Fused deposition modeling (FDM) is a commonly utilized method of 3D printing anatomical models due to its cost-effectiveness. A potential disadvantage of FDM 3D printing complex anatomical shapes is the limitations of the modeling system in providing accurate representations of multifaceted ultrastructure, such as the facets of the lumbar spine. In order to utilize FDM 3D printing methods in an efficient manner, the pre-printing G-code assembly must be oriented according to the anatomical nature of the print. This article describes the approach that our institution's 3D printing laboratory has used to manipulate models’ printing angles in regard to the print bed and nozzle, according to anatomical properties, thus creating quality and cost-effective anatomical spine models for education and procedural simulation. 

Hybrid computed tomography and magnetic resonance imaging 3D printed models for neurosurgery planning

In the last decade, the clinical applications of three-dimensional (3D) printed models, in the neurosurgery field among others, have expanded widely based on several technical improvements in 3D printers, an increased variety of materials, but especially in postprocessing software. More commonly, physical models are obtained from a unique imaging technique with potential utilization in presurgical planning, generation/creation of patient-specific surgical material and personalized prosthesis or implants. Using specific software solutions, it is possible to obtain a more accurate segmentation of different anatomical and pathological structures and a more precise registration between different medical image sources allowing generating hybrid computed tomography (CT) and magnetic resonance imaging (MRI) 3D printed models. The need of neurosurgeons for a better understanding of the complex anatomy of central nervous system (CNS) and spine is pushing the use of these hybrid models, which are able to combine morphological information from CT and MRI, and also able to add physiological data from advanced MRI sequences, such as diffusion-weighted imaging (DWI), diffusion tensor imaging (DTI), perfusion weighted imaging (PWI) and functional MRI (fMRI). The inclusion of physiopathological data from advanced MRI sequences enables neurosurgeons to identify those areas with increased biological aggressiveness within a certain lesion prior to surgery or biopsy procedures. Preliminary data support the use of this more accurate presurgical perspective, to select the better surgical approach, reduce the global length of surgery and minimize the rate of intraoperative complications, morbidities or patient recovery times after surgery. The use of 3D printed models in neurosurgery has also demonstrated to be a valid tool for surgeons training and to improve communication between specialists and patients. Further studies are needed to test the feasibility of this novel approach in common clinical practice and determine the degree of improvement the neurosurgeons receive and the potential impact on patient outcome.

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.

The Future of Biomechanical Spine Research: Conception and Design of a Dynamic 3D Printed Cervical Myelography Phantom

Background

Three-dimensional (3D) printing is a growing practice in the medical community for patient care and trainee education as well as production of equipment and devices. The development of functional models to replicate physiologic systems of human tissue has also been explored, although to a lesser degree. Specifically, the design of 3D printed phantoms that possess comparable biomechanical properties to human cervical vertebrae is an underdeveloped area of spine research. In order to investigate the functional uses of cervical 3D printed models for replicating the complex physiologic and biomechanical properties of the human subaxial cervical spine, our institution has created a prototype that accurately reflects these properties and provides a novel method of assessing spinal canal dimensions using simulated myelography. To our knowledge, this is the first 3D printed phantom created to study these parameters.

Materials and methods

A de-identified cervical spine computed tomography imaging file was segmented using threshold modulation in 3D Slicer software. The subaxial vertebrae (C3-C7) of the scan were individualized by separating the facet joint spaces and uncovertebral joints within the software in order to create individual stereolithography (STL) files. Each individual vertebra was printed on an Ultimaker S5 dual-extrusion printer using white “tough” polylactic acid filament. A human cadaveric subaxial cervical spine was harvested to provide a control for our experiment. Both models were assessed and compared in flexion and extension dynamic motion grossly and fluoroscopically. The maximum angles of deformation on X-ray imaging were recorded using DICOM (Digital Imaging and Communications in Medicine) viewing software. In order to compare the ability to assess canal dimensions of the models using fluoroscopic imaging, a myelography simulation was designed.

Results

The cervical phantom demonstrated excellent ability to resist deformation in flexion and extension positions, attributed to the high quality of initial segmentation. The gross and fluoroscopic dynamic movement of the phantom was analogous to the cadaver model. The myelography simulator adequately demonstrated the canal dimensions in static and dynamic positions for both models. Pertinent anatomic landmarks were able to be effectively visualized for assessment of canal measurements for sagittal and transverse dimensions.

Conclusions

By utilizing the latest technologies in DICOM segmentation and 3D printing, our institution has created the first cervical myelography phantom for biomechanical evaluation and trainee instruction. By combining new technologies with anatomical knowledge, quality 3D printing shows great promise in becoming a standard player in the future of spinal 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.