Engineering Assisted Surgery™: A route for digital design and manufacturing of customised maxillofacial implants

Lohfeld, Stefan; McHugh, Peter E.; Serban, D.; Boyle, D.; O’Donnell, Garret E.; Peckitt, Ninian S.

doi:10.1016/j.jmatprotec.2006.10.028

Cited by 24 publications

(15 citation statements)

References 16 publications

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“…The viable possibilities of the internal structure were selected and the implant model was built; this time, it was not completely filled, but with an internal configuration with controlled porosity, as shown in Figure 7. As described by Lohfeld et al [15], a hollow prosthesis not only benefits from being light weight, but can be produced more rapidly. The production time of this process strongly depends on the area to be scanned with the laser in each layer.…”

Section: Resultsmentioning

confidence: 99%

“…In some studies, digital design and RP techniques were used for direct manufacturing of an implant model [14], but they do not make references to any suitable material for implantation. Lohfeld et al [15] demonstrated the generation of customized prosthesis using a standard digital design route and a manufacturing process. However, the literature review confirms that there have been no major publications involving design and manufacturing of customized prostheses with suitable materials used for implantation.…”

Section: Introductionmentioning

confidence: 99%

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Design and health care: a study of virtual design and direct metal laser sintering of titanium alloy for the production of customized facial implants

Bertol¹,

Silva²,

Kindlein³

2008

AMJ

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The increase in life expectancy and a great number of accidents lead to higher demand for medical products, including corrective implants. Patients with tumors or traumas need to replace injured areas in order to restore their aesthetic and structural function. Currently, the available craniofacial implants present a standard geometry and seldom generate satisfactory results. Customized implants, on the other hand, are designed to conform exactly to individual patient's anatomy. This way, the use of customized implants can show beneficial effects to the patient and the surgical team. In this study, the design and manufacturing of customized implant prior to surgery were described. Implant shape and functional requirements were established by digital data based on CT-scans and mirroring operations. The design process of customized mandible prosthesis is illustrated as well as its manufacturing process (direct metal laser sintering) and quality control. Laser sintering process and its constraints for the production of customized implants in titanium alloy (Ti-6Al-4V) with complex geometry and internal structures are reported.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Design and health care: a study of virtual design and direct metal laser sintering of titanium alloy for the production of customized facial implants

Bertol¹,

Silva²,

Kindlein³

2008

AMJ

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“…With the ability to accurately fabricate structures based on CT data, SLS/SLM can be used to produce patient-specific prostheses and other medical devices. Recent studies have demonstrated that nasal and maxillary prosthetics fabricated using SLS/SLM may be implanted into the human body [36,37]. In addition, SLS enabled tissue-engineering scaffolds with 50 μm features to be fabricated.…”

Section: Selective Laser Sintering/meltingmentioning

confidence: 99%

“…In addition, SLS enabled tissue-engineering scaffolds with 50 μm features to be fabricated. Lohfeld et al and Williams et al have demonstrated the use of SLS in tissue engineering [37,38]. Using micro-CT (μCT) and SLS, Partee et al fabricated structures for use as tissue-engineering scaffolds [39].…”

Section: Selective Laser Sintering/meltingmentioning

confidence: 99%

Laser direct writing of micro- and nano-scale medical devices

Gittard

Narayan

2010

Expert Review of Medical Devices

137

105

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Laser-based direct writing of materials has undergone significant development in recent years. The ability to modify a variety of materials at small length scales and using short production times provides laser direct writing with unique capabilities for fabrication of medical devices. In many laser-based rapid prototyping methods, microscale and submicroscale structuring of materials is controlled by computer-generated models. Various laser-based direct write methods, including selective laser sintering/melting, laser machining, matrix-assisted pulsed-laser evaporation direct write, stereolithography and two-photon polymerization, are described. Their use in fabrication of microstructured and nanostructured medical devices is discussed. Laser direct writing may be used for processing a wide variety of advanced medical devices, including patient-specific prostheses, drug delivery devices, biosensors, stents and tissue-engineering scaffolds.

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“…The anatomical areas in which the RP technology has been successfully applied at international level are: maxilla-facial reconstruction; knee surgery; pelvic fractures; hip dysplasia, aseptic necrosis and epiphysiolysis; pinal trauma; congenital and degenerative spinal disease; skull plasticities; craniosynostosis and orthodontic surgery (Truscott et al, 2004;Gopakumar, 2004;Petzold et al, 1999;Joshi et al, 2006;Sekou et al, 2009;Chua et al, 2000). Medical models were built using predominantly, the stereolithography (STL) and the fused deposition modeling (FDM) techniques of RP over the last few years (Winder and Bibb, 2005 integrated approach of the medical imaging, computer-aided design (CAD), RP and computer-aided manufacturing (CAM) for fabricating the customised medical implants reduces lead time (Hieu et al, 2003;Lohfeld et al, 2007). It is also common to use computer numerical controlled (CNC) machining to get an accurate customised design of the implant (Penkner et al, 1999).…”

Section: Introductionmentioning

confidence: 99%

Rapid prototyping assisted fabrication of the customised temporomandibular joint implant: a case report

Deshmukh¹,

Kuthe

Chaware

et al. 2011

Rapid Prototyping Journal

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Purpose -The purpose of this paper was to find a successful treatment modality for patients suffering from temporomandibular joint (TMJ) ankylosis who could not be treated through traditional surgeries. Design/methodology/approach -This work integrated the unique capabilities of the imaging technique, the rapid prototyping (RP) technology and the advanced manufacturing technique to develop the customised TMJ implant. The patient specific TMJ implant was fabricated using the computed tomography scanned data and the fused deposition modeling of RP for the TMJ surgery.Findings -This approach showed good results in fabrication of the TMJ implant. Postoperatively, the patient experienced normalcy in the jaw movements. Practical implications -Advanced technologies helped to fabricate the customised TMJ implant. The advantage of this approach is that the physical RP model assisted in designing the final metallic implant. It also helped in the surgical planning and the rehearsals. Originality/value -This case report illustrates the benefits of imaging/computer-aided design/computer-aided manufacturing/RP to develop the customised implant and serve those patients who could not be treated in the traditional way.

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Engineering Assisted Surgery™: A route for digital design and manufacturing of customised maxillofacial implants

Cited by 24 publications

References 16 publications

Design and health care: a study of virtual design and direct metal laser sintering of titanium alloy for the production of customized facial implants

Design and health care: a study of virtual design and direct metal laser sintering of titanium alloy for the production of customized facial implants

Laser direct writing of micro- and nano-scale medical devices

Rapid prototyping assisted fabrication of the customised temporomandibular joint implant: a case report

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