The article was first published on the polskiprzemysl.com.pl website on 1 July 2020
Additive manufacturing is a rapidly evolving technology with significant potential in various sectors, including medicine, automotive and aviation. In the medical field, this technology is not only opening new frontiers in transplantology (bioprinting) but is also finding crucial applications in surgery and pre-operative planning.
Since the introduction of medical imaging technology over a century ago, doctors have become accustomed to working in two dimensions. X-rays, computed tomography or PET-CT and MRI (magnetic resonance imaging) provide invaluable information to medical staff by creating two-dimensional representations of the examined or treated part of the body.
3D printing in medical imaging
However, the human body exists in three dimensions, and modern medicine is becoming increasingly personalised. Gaining in-depth insight into three-dimensional pathological changes from two-dimensional models requires a certain degree of visualisation skills, which is often challenging for surgeons.
There is a general lack of individual characteristics in traditional 2D models, which are encountered in the real world of anatomy and complex pathological changes.
Similarly, general 3D models lack detailed patient data, which could have a significant effect on the outcome of surgery. In the fields of orthopaedics (spinal surgery), maxillofacial surgery, neurosurgery, cardiac surgery, and others, the rapid prototyping of anatomical models — patient-specific guides derived from actual imaging — is transforming the landscape of surgery. The model allows surgeons to more accurately assess the size and shape of the anatomical defect, facilitating a more efficient surgery. This results in reduced anaesthesia time, consequently minimising complications, particularly strokes.
Preoperative 3D-printed organ models
3D printing has been shown to contribute to significantly enhanced diagnostics and education in surgery. This has been confirmed by hospitals that have used 3D-printed organ models for trial operations of complex surgical cases.
One notable example is Great Ormond Street Hospital in London, where a complex surgical procedure was successfully performed to separate twins, Safa and Marwa, who were born with conjoined skulls.
Thanks to a colour replica of the girls’ unique anatomy, printed in HP 3D printing technology, doctors were able to better prepare for the highly complex procedure long before entering the operating theatre. Mapping of the veins, arteries and other internal structures, followed by development of several different surgical treatment strategies based on the clinical problem, allowed prevention of complications and problems that are often encountered during such operations.
3D-printed organ models are also invaluable in preoperative patient education, an important aspect of any major surgery. These personalised models, based on the patient’s anatomy, help surgeons better illustrate and explain both the pathologies present and the procedures required to correct them.
Case study: Rady Children’s Hospital
Rady Children’s Hospital has successfully implemented 3D printing technology (FDM) in its orthopaedic and cardiac surgery departments for several years. These models are primarily used for procedural and surgical planning, but also for educational purposes, helping to explain patients’ conditions and planned surgery to both students and patients.
Rady Children’s Hospital was encountering challenges with its approach to printing anatomical models. The hospital could only produce two models per month using outsourcing, and the associated costs were significant, ranging from PLN 2,300 for smaller models to PLN 4,700 for larger ones. In response, the hospital sought a solution to address these issues, with the primary objectives being reduced lead times, lower printing costs and, most importantly, an enhancement in the quality of 3D prints.
Models produced using fused deposition modelling (FDM) technology were not durable and were prone to breakage, necessitating frequent replication. The opening of the new branch has seen the introduction of a new technology, HP Multi Jet Fusion 3D, which offers very high strength and flexibility as well as the most uniform mechanical properties of printed plastic components (PA 11 and PA 12, TPU, PP).
Dr Ryan, the head of the new department at Rady Children’s Hospital, has also highlighted the significance of HP MJF 3D technology in enabling colour 3D printing. He emphasises that this capability is crucial in terms of both cost efficiency and the quality of imaging, as colour enhances the ability of clinicians and patients to comprehend the intricacies of anatomy when preparing for surgery.
He explains that one minute in the operating theatre costs around EUR 60. Therefore, by shortening the duration of the operation thanks to training on colourful preoperative models, the hospital can make significant savings. Another benefit is the shorter production time for the models themselves. Using HP MJF 3D technology, Dr Ryan can obtain them within a single day.
Personalised medical tools and equipment
Additive technologies, such as HP MJF 3D, offer the potential for the customised production of surgical tools and non-standard medical equipment.
These tools can be tailored to the specific requirements of a procedure or the practitioner, providing a high degree of customisation. The use of additive technologies allows for the creation of tools that are designed according to the anatomy of each patient or the special needs of the doctor.
HP3D.pl is a leading distributor of HP Multi Jet Fusion technology in Poland, specialising in providing comprehensive solutions to clinics and patients. Our offerings encompass a wide range of products and services, including software, 3D scanners, HP devices for the production of anatomical models and personalised surgical and rehabilitation tools. In addition, we offer various other solutions dedicated to the medical industry.
The medical industry has always required affordable, reliable instruments; however, the challenge has been that treatment needs vary due to the uniqueness of each patient. 3D printing, particularly HP MJF 3D technology, facilitates the creation of customised instruments, enabling a more personalised surgical process. This results in shorter procedures and lower operating costs.
