(1) Background: In recent years, three-dimensional (3D) templates have replaced traditional two-dimensional (2D) templates as visual guides during intra-operative carving of the autogenous cartilage framework in microtia reconstruction. This study aims to introduce a protocol of the fabrication of patient-specific, 3D printed and sterilizable auricular models for autogenous auricular reconstruction. (2) Methods: The patient’s unaffected ear was captured with a high-resolution surface 3D scan (Artec Eva) and post-processed in order to obtain a clean surface model (STL format). In the next step, the ear was digitally mirrored, segmented and separated into its component auricle parts for reconstruction. It was disassembled into helix, antihelix, tragus and base and a physical model was 3D printed for each part. Following this segmentation, the cartilage was carved in the operating room, based on the models. (3) Results: This segmentation technique facilitates the modeling and carving of the scaffold, with adequate height, depth, width and thickness. This reduces both the surgical time and the amount of costal cartilage used. (4) Conclusions: This segmentation technique uses surface scanning and 3D printing to produce sterilizable and patient-specific 3D templates.

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Virtual surgical planning allows orthognathic surgeons to design a surgical plan preoperatively and establish a personalized surgical protocol. This study aims to validate the predictability and accuracy of orthognathic surgery through a comparison of the three-dimensional (3D) models of the virtual planning and postoperative CBCT using free software (3D Slicer) on 40 patients who underwent bimaxillary orthognathic surgery. The distances of point A, point B, pogonion (Pog), and the first upper and lower molars, both in each axis (x, y, and z) and in the 3D space, were analyzed. The median of the distances in the mediolateral direction was the lowest, while the highest differences were found at point A and Pog in the anteroposterior direction (0.83 mm and 0.78 mm, respectively). Vertical differences were higher in the maxilla than in the mandible. In conclusion, we found that orthognathic bimaxillary surgery using virtual surgical planning was more accurate when positioning the bone segments in the mediolateral direction, using the information provided by the splint, as well as when positioning the mandible compared to the maxilla.

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The purpose of this study was to perform a quantitative and qualitative validation of a soft tissue simulation pipeline for orthognathic surgery planning, necessary for clinical use. Simulation results were retrospectively obtained in 10 patients who underwent orthognathic surgery. Quantitatively, error was measured at 9 anatomical landmarks for each patient and different types of comparative analysis were performed considering two mesh resolutions, clinically accepted error, simulation time and error measured by means of percentage of the whole surface. Qualitatively, evaluation and binary questions were asked to two surgeons, both before and after seeing the actual surgical outcome, and their answers were compared. Finally, the quantitative and qualitative results were compared to check if these two types of validation are correlated. The quantitative results were accurate, with greater errors corresponding to gonions and lower lip. Qualitatively, surgeons answered similarly mostly and their evaluations improved when seeing the actual outcome of the surgery. The quantitative validation was not correlated to the qualitative validation. In this study, quantitative and qualitative validations were performed and compared, and the need to carry out both types of analysis in validation studies of soft tissue simulation software for orthognathic surgery planning was proved.