T medical rapid prototyping in custom implant design for craniofacial reconstruction

Trauma, cranial tumors, infected craniotomy bone flaps and external neurosurgical decompression are the main causes for large cranial defects. The success of the reconstructive craniofacial surgery depends on good preoperative evaluation of the deformity, formation of the surgical planning, preparation of precise-fitting implants, and accurate execution of the operation. Recently, reversing engineering and rapid prototyping technologies have been applied to produce physical models in various medical applications. In this article, the applications of 3-dimensional medical image reconstruction and rapid prototyping techniques were used for implant design and production of implant for patient with large cranial defect reconstruction. The medical images were manipulated and surgical planning was performed in virtual environment by moving the image objects. The customized implant was prefabricated based on the 3-dimensional image created to cover the cranial defect. A skull model is also produced for real touch evaluation, surgical planning and rehearsal of surgical procedures. The results show that both of 3-dimensional medical image model and physical skull model were helpful for planning of craniofacial surgery and design of customized implant. The surgery result was satisfactory without complication. Particular advantage was the unlimited trials in surgical simulation for using imaging model, and the close-to-reality surgical rehearsal for using physical model.