Geometric accuracy of an acrylonitrile butadiene styrene canine tibia model fabricated using fused deposition modelling and the effects of hydrogen peroxide gas plasma sterilisation

Abstract

Background Three-dimensional (3D) printing techniques have been used to produce anatomical models and surgical guiding instruments in orthopaedic surgery. The geometric accuracy of the 3D printed replica may affect surgical planning. This study assessed the geometric accuracy of an acrylonitrile butadiene styrene (ABS) canine tibia model printed using fused deposition modelling (FDM) and evaluated its morphological change after hydrogen peroxide (H2O2) gas plasma sterilisation. The tibias of six canine cadavers underwent computed tomography for 3D reconstruction. Tibia models were fabricated from ABS on a 3D printer through FDM. Reverse-engineering technology was used to compare morphological errors (root mean square; RMS) between the 3D-FDM models and virtual models segmented from original tibia images (3D-CT) and between the models sterilised with H2O2 gas plasma (3D-GAS) and 3D-FDM models on tibia surface and in cross-sections at: 5, 15, 25, 50, 75, 85, and 95% of the tibia length. Results The RMS mean ± standard deviation and average positive and negative deviation values for all specimens in EFDM-CT (3D-FDM vs. 3D-CT) were significantly higher than those in EGAS-FDM (3D-GAS vs. 3D-FDM; P < 0.0001). Mean RMS values for EFDM-CT at 5% bone length (proximal tibia) were significantly higher than those at the other six cross-sections (P < 0.0001). Mean RMS differences for EGAS-FDM at all seven cross-sections were nonsignificant. Conclusions The tibia models fabricated on an FDM printer had high geometric accuracy with a low RMS value. The surface deviation in EFDM-CT indicated that larger errors occurred during manufacturing than during sterilisation. Therefore, the model may be used for surgical rehearsal and further clinically relevant applications in bone surgery. Graphical abstract

Low-Cost Cranioplasty—A Systematic Review of 3D Printing in Medicine

“…According to Toro et al, vaporized hydrogen peroxide sterilization provides dimensional stability for sterilized ABS-3D printed elements [ 223 ]. The same was reported by other authors [ 224 , 225 ]. PEEK implants are known to retain their mechanical properties after multiple steam sterilization cycles [ 226 , 227 ].…”

Fused deposition modelling: Current status, methodology, applications and future prospects

“…Multi-colour extrusion FDM has been used as a low-cost 3D printing method for anatomical prostate cancer models [53]. An acrylonitrile butadiene styrene (ABS) canine tibia model [54] and complete dentures have been fabricated by FDM [55].…”

Sterilization of PLA after Fused Filament Fabrication 3D Printing: Evaluation on Inherent Sterility and the Impossibility of Autoclavation

“…As Oth et al (2019) point out, chemical sterilization such as peroxide plasma ethylene oxide is a suitable method for genioplasty cutting guides made of PLA and PETG (polyethylene terephthalate glycol), which both suffer from deformation in the sub-millimeter range [ 14 ]. In addition, other studies name high costs, toxic hazardous residues, and in-contrast deformations on the sterilized product in short- and long-term sterilization [ 9 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 ]; One of the most frequently used methods is autoclaving. Its roots are in the 17th century, when Denis Papin experimented with his “Steam Digester” [ 20 ].…”