Reimagining innovation in cranial reconstruction: Virtual planning and cost effectiveness of additive manufacturing

Abstract

This study aims to reconstruct cranial defect for virtual surgical planning and assess the cost-effectiveness of four different additive manufacturing techniques whenever 3D printing of cranial mould is required for actual reconstruction purpose. 3D images of the skull with cranial defect were obtained and segmented using an image processing software followed by generation of a virtual 3D model. The defect part was reconstructed to obtain a patient-specific implant. Computer aided design software was then used to design a mould. The mould was transferred to four different additive manufacturing machines of fused deposition modelling (FDM), selective laser sintering (SLS), multi-jet modelling (MJM) and stereolithography (SLA) to assess the material consumption and printing time for cost estimation purpose. The implant fit the defect part and the mould was successfully fabricated from the designed implant. 3D printing of a mould using an FDM technique significantly reduced the material consumption, hence reduced the cost to be borne by patient. Virtual reconstruction allows surgeon to visualise the defect condition prior to actual operation, while exploration of the cost of different 3D printing techniques provides more option for patient with cranial defect to obtain regular cosmesis at a reasonable cost