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Purpose In minimally invasive spring-assisted craniectomy, surgeons plan the surgery by manually locating the cranial sutures. However, this approach is prone to error. Augmented reality (AR) could be used to visualize the cranial sutures and assist in the surgery planning. The purpose of our work is to develop an AR-based system to visualize cranial sutures, and to assess the accuracy and usability of using AR-based navigation for surgical guidance in minimally invasive spring-assisted craniectomy. Methods An AR system was developed that consists of an electromagnetic tracking system linked with a Microsoft HoloLens. The system was used to conduct a study with two skull phantoms. For each phantom, five sutures were annotated and visualized on the skull surface. Twelve participants assessed the system. For each participant, model alignment using six anatomical landmarks was performed, followed by the participant delineation of the visualized sutures. At the end, the participants filled a system usability scale (SUS) questionnaire. For evaluation, an independent optical tracking system was used and the delineated sutures were digitized and compared to the CT-annotated sutures. Results For a total of 120 delineated sutures, the distance of the annotated sutures to the planning reference was $$2.4\pm 1.2$$ 2.4 ± 1.2  mm. The average delineation time per suture was $$13\pm 5$$ 13 ± 5  s. For the system usability questionnaire, an average SUS score of 73 was obtained. Conclusion The developed AR-system has good accuracy (average 2.4 mm distance) and could be used in the OR. The system can assist in the pre-planning of minimally invasive craniosynostosis surgeries to locate cranial sutures accurately instead of the traditional approach of manual palpation. Although the conducted phantom study was designed to closely reflect the clinical setup in the OR, further clinical validation of the developed system is needed and will be addressed in a future work.

Augmented reality (AR) permits the visualization of pre-operative data in the surgical field of view of the surgeon. This requires the alignment of the AR device’s coordinate system with the used navigation/tracking system. We propose a multimodal marker approach to align an AR device with a tracking system: in our implementation, an electromagnetic tracking system (EMTS). The solution makes use of a calibration method which determines the relationship between a 2D pattern detected by an RGB camera and an electromagnetic sensor of the EMTS. This allowed the projection of a 3D skull model on its physical counterpart. This projection was evaluated using a monocular camera and an optical see-through device (HoloLens 2) (https://www.microsoft.com/en-us/hololens/) achieving an accuracy of less than 2.5 mm in the image plane of the HoloLens 2 (HL2). Additionally, 10 volunteers participated in a user study consisting of an alignment task of a pointer with 25 projections viewed through the HL2. The participants achieved a mean error of 2.7 1.3 mm and 2.9 2.9$$^\circ $$ ∘ in positional and orientation error. This study showcases the feasibility of the approach, provides an evaluation of the alignment, and finally, discusses its advantages and limitations.

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