Summary Microtia reconstruction using autologous costal cartilage can be one of the most challenging tasks in reconstructive surgery. An intraoperative guide using 2-dimentional drawing of the contralateral ear on an x-ray film remains the current standard of care. In this paper, we present the use of computer-aided design and desktop 3D printing to fabricate low cost, sterilizable auricular carving templates to serve as a peri-operative reference for microtia reconstruction. The design was made as a single component which incorporated the usual anatomic reference points of the ear based on Nagata technique as a Stereo-lithography file format (. STL) for 3D printing. The templates were created in sizes ranging from 55 mm to 70 mm with a 2 mm increment with an average production cost of 0.26 US dollars per material per template and about 4.5 US dollars for the whole set. Individual templates were then 3D-printed using a thermoplastic polyurethane (TPU 95A) semiflexible filament on a desktop fused deposition modeling, Ultimaker 2 + 3D printer. The produced template tolerated the sterilization process with no structural changes as compared to its pre-sterilization condition. In conclusion, we present cost-effective, sterilizable, multiscale auricular templates to guide the pre- and intra-operative carving of the cartilaginous framework during microtia reconstruction with more accuracy in a time efficient manner, thereby overcoming the drawbacks of using the traditional x-ray film. The templates are readily accessible and sharable for free through open-source software and can be directly 3D-printed using an affordable desktop 3D printer.

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Background: Microsurgical anastomosis is a technically demanding skill. The most difficult part of the learning process was in achieving the necessary orientation and dexterity. In this project, we adopted computer-aided design and desktop 3D-printing in the development of an affordable training model with different levels of vessel orientation and angulation. Methods: The training model was designed using CAD software (Rhino3D). The models were then 3D-printed with a thermoplastic polyurethane (TPU 95A) semiflexible filament on a desktop fused deposition modeling, Ultimaker 2 + 3D printer. Results: The printed training tool was assembled by fitting the ball-and-socket mechanism between two parts having an overall round table top with integrated vascular clamps. Trial with synthetic and nonliving animal blood vessels shows the utility of the clamps in holding the vessels within the working space. By rotating the top part, a multiaxial vessel orientation from 0 to 360 degrees was achieved. The top part was also capable of multiangular orientation of the vessels (±30 degrees) regardless of its axial orientation during vessel anastomosis. For the 3D-printing process, the average printing time was about 3.5 hours with a cost of 1.3$ per material. Conclusions: The utility of desktop 3D printing represents an affordable modality in microsurgical training. The designed model is capable of providing a trainee with multiaxial and multiangular vessel orientation during the anastomosis process. To our knowledge, the adoption of this technology in the field of microsurgery training has never been investigated before.