Bone reconstruction surgery of complex craniomaxillofacial deformities using additive manufacturing customized implants - a case report

Abstract

Purpose

This study aims to assess the design, manufacturing and surgical implantation of three-dimensional (3D) customized implants, including surgical preoperative planning, surgery and postoperative results, for cranioplasty along with zygomatic and orbital floor implants using additive manufacturing (AM) technics for a 23-year-old female who suffered from severe craniomaxillofacial trauma.

Design/methodology/approach

The skull biomodel was produced in polyamide while implants were made of Ti-6Al-4V alloy by AM.

Findings

The method enabled perfectly fitting implants and anatomical conformance with the craniomaxillofacial defect, providing complete healing for the patient. Surgical planning using a customized 3D polyamide biomodel was effective. This proved to be a powerful tool for medical planning and manufacturing of customized implants, as complete healing and good craniofacial aesthetic results were observed.

Originality/value

Satisfactory surgical procedures, regarding surgery time reduction and good craniofacial aesthetic results, were achieved. Furthermore, the 3D titanium customized implants represented a favorable alternative for the repair of craniomaxillofacial defects.

Citation

Jardini, A.L., Najar Lopes, É.S., Gabriel, L.P., Calderoni, D., Maciel Filho, R. and Kharmandayan, P. (2021), "Bone reconstruction surgery of complex craniomaxillofacial deformities using additive manufacturing customized implants - a case report", Rapid Prototyping Journal, Vol. 27 No. 5, pp. 872-878. https://doi.org/10.1108/RPJ-07-2020-0169