3D printing from diagnostic images: a radiologist’s primer with an emphasis on musculoskeletal imaging—putting the 3D printing of pathology into the hands of every physician

Abstract

Three-dimensional (3D) printing has recently erupted into the medical arena due to decreased costs and increased availability of printers and software tools. Due to lack of detailed information in the medical literature on the methods for 3D printing, we have reviewed the medical and engineering literature on the various methods for 3D printing and compiled them into a practical "how to" format, thereby enabling the novice to start 3D printing with very limited funds. We describe (1) background knowledge, (2) imaging parameters, (3) software, (4) hardware, (5) post-processing, and (6) financial aspects required to cost-effectively reproduce a patient's disease ex vivo so that the patient, engineer and surgeon may hold the anatomy and associated pathology in their hands.

Logistics of Three-dimensional Printing

“…The printer costs range from $150 to $500,000 while the material costs range from a few to several thousand dollars (8, 9). Print times can range from minutes to days, depending on the model complexity and materials used.…”

“…The material hardens upon cooling and the subsequent layer is then created. This technique is analogous to the mechanism behind a hot glue gun (8). …”

“…Disadvantages are that the resolution for fine details is limited and the model is initially soft until the material hardens, so overhanging parts need to be supported until hardening (10). Additionally, printing times can vary depending on material used since each layer must partially cool before the successive layer is applied (8). The cost also varies depending on the printer used, with large scale commercial printers often requiring more expensive materials (>$100/kg) but producing higher quality models than smaller desktop FDM printers.…”

“…The cost also varies depending on the printer used, with large scale commercial printers often requiring more expensive materials (>$100/kg) but producing higher quality models than smaller desktop FDM printers. Toxic fumes can also be produced during the manufacturing process, and adequate ventilation is required, which can add to the expense of the printing process (8, 11). …”

“…The energy source is applied to a thin bed of powder on the build tray, causing the particles to melt and fuse (8). The powder bed then lowers and the subsequent layer is created.…”