Design of thermoformable three dimensional-printed PLA cast for fractured wrist

Abstract Patient specific plastic cast for broken limbs has been developed recently in pharmaceutical field through three-dimensional (3D) printing method. However, the production of a 3D printed cast through normal 3D printing method is time consuming compared to conventional plaster casting. In this study, a design of ventilated structured thermoformable 3D-printed polylactic acid (PLA) cast was produced as an alternative for the 3D printed cast production method. This design was initially printed in a flat shape and then transformed into a cast which can be fitted to the user’s arm by using heat and external force. Finite Element Analysis (FEA) method was used to assess the mechanical properties of the proposed cast. In this analysis, thethermoformable design was exerted with a distributed force of 400 N, which is larger than the loading conditions encountered by human in their daily life. The mechanical properties of the thermoformable PLA cast such as local displacement under a specific load, maximum load, and stress were evaluated. Results were compared with the mechanical properties of Plaster of Paris cast. The results obtained from the FEA indicates that at the same layer thickness, the thermoformable 3D-printed PLA cast is stronger than the Plaster of Paris cast.

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Investigation of three-dimensional printing materials for printing aorta model replicating Type B aortic dissection

Current Medical Imaging Formerly Current Medical Imaging Reviews ◽

10.2174/1573405617666210218102046 ◽

2021 ◽

Vol 17 ◽

Author(s):

Chia-An Wu ◽

Andrew Squelch ◽

Zhonghua Sun

Keyword(s):

3D Printing ◽

Aortic Dissection ◽

Three Dimensional ◽

Ct Images ◽

Patient Specific ◽

Type B ◽

Type B Aortic Dissection ◽

Ct Attenuation ◽

Significant Difference ◽

3D Printed

Aim: To determine a printing material that has both elastic property and radiology equivalence close to real aorta for simulation of endovascular stent graft repair of aortic dissection. Background: With the rapid development of three-dimensional (3D) printing technology, a patient-specific 3D printed model is able to help surgeons to make better treatment plan for Type B aortic dissection patients. However, the radiological properties of most 3D printing materials have not been well characterized. This study aims to investigate the appropriate materials for printing human aorta with mechanical and radiological properties similar to the real aortic computed tomography (CT) attenuation. Objective: Quantitative assessment of CT attenuation of different materials used in 3D printed models of aortic dissection for developing patient-specific 3D printed aorta models to simulate type B aortic dissection. Method: A 25-mm length of aorta model was segmented from a patient’s image dataset with diagnosis of type B aortic dissection. Four different elastic commercial 3D printing materials, namely Agilus A40 and A50, Visijet CE-NT A30 and A70 were selected and printed with different hardness. Totally four models were printed out and conducted CT scanned twice on a 192-slice CT scanner using the standard aortic CT angiography protocol, with and without contrast inside the lumen.Five reference points with region of interest (ROI) of 1.77 mm2 were selected at the aortic wall and intimal flap and their Hounsfield units (HU) were measured and compared with the CT attenuation of original CT images. The comparison between the patient’s aorta and models was performed through a paired-sample t-test to determine if there is any significant difference. Result: The mean CT attenuation of aortic wall of the original CT images was 80.7 HU. Analysis of images without using contrast medium showed that the material of Agilus A50 produced the mean CT attenuation of 82.6 HU, which is similar to that of original CT images. The CT attenuation measured at images acquired with other three materials was significantly lower than that of original images (p<0.05). After adding contrast medium, Visijet CE-NT A30 had an average CT attenuation of 90.6 HU, which is close to that of the original images with statistically significant difference (p>0.05). In contrast, the CT attenuation measured at images acquired with other three materials (Agilus A40, A50 and Visiject CE-NT A70) was 129 HU, 135 HU and 129.6 HU, respectively, which is significantly higher than that of original CT images (p<0.05). Conclusion: Both Visijet CE-NT and Agilus have tensile strength and elongation close to real patient’s tissue properties producing similar CT attenuation. Visijet CE-NT A30 is considered the appropriate material for printing aorta to simulate contrast-enhanced CT imaging of type B aortic dissection. Due to lack of body phantom in the experiments, further research with simulation of realistic anatomical body environment should be conducted.

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Three-dimensional Printing Versus Conventional Machining in the Creation of a Meatal Urethral Dilator: a Cost and Mechanical Strength Analysis

10.21203/rs.3.rs-28817/v1 ◽

2020 ◽

Author(s):

Michael Yue-Cheng Chen ◽

Jacob Skewes ◽

Ryan Daley ◽

Maria Ann Woodruff ◽

Nicholas John Rukin

Keyword(s):

3D Printing ◽

Three Dimensional ◽

Patient Specific ◽

Strength Analysis ◽

Fused Deposition Modelling ◽

3D Printer ◽

Current Time ◽

Fused Deposition ◽

3D Printed ◽

Conventional Machining

Abstract BackgroundThree-dimensional (3D) printing is a promising technology but the limitations are often poorly understood. We compare different 3D printingmethods with conventional machining techniques in manufacturing meatal urethral dilators which were recently removed from the Australian market. MethodsA prototype dilator was 3D printed vertically orientated on a low cost fused deposition modelling (FDM) 3D printer in polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS). It was also 3D printed horizontally orientated in ABS on a high-end FDM 3D printer with soluble support material, as well as on a SLS 3D printer in medical nylon. The dilator was also machined in stainless steel using a lathe. All dilators were tested mechanically in a custom rig by hanging calibrated weights from the handle until the dilator snapped. ResultsThe horizontally printed ABS dilator experienced failure at a greater load than the vertically printed PLA and ABS dilators respectively (503g vs 283g vs 163g, p < 0.001). The SLS nylon dilator and machined steel dilator did not fail. The steel dilator is most expensive with a quantity of five at 98 USD each, but this decreases to 30 USD each for a quantity of 1000. In contrast, the cost for the SLS dilator is 33 USD each for five and 27 USD each for 1000. ConclusionsAt the current time 3D printing is not a replacement for conventional manufacturing. 3D printing is best used for patient-specific parts, prototyping or manufacturing complex parts that have additional functionality that cannot otherwise beachieved.

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Patient-specific 3D-Printed Splint for Mallet Finger Injury

International Journal of Bioprinting ◽

10.18063/ijb.v6i2.259 ◽

2020 ◽

Vol 6 (2) ◽

Author(s):

Ali Zolfagharian ◽

Timothy M Gregory ◽

Mahdi Bodaghi ◽

Saleh Gharaie ◽

Pearse Fay

Keyword(s):

3D Printing ◽

Heat Dissipation ◽

Treatment Options ◽

Three Dimensional ◽

Patient Specific ◽

Mallet Finger ◽

Element Analysis ◽

Finger Injury ◽

Potential Efficacy ◽

Specific Complex

Despite the frequency of mallet finger injuries, treatment options can often be costly, time-consuming, and ill-fitted. Three-dimensional (3D) printing allows for the production of highly customized and inexpensive splints, which suggests potential efficacy in the prescription of casts for musculoskeletal injuries. This study explores how the use of engineering concepts such as 3D printing and topology optimization (TO) can improve outcomes for patients. 3D printing enables the direct fabrication of the patient-specific complex shapes while utilizing finite element analysis and TO in the design of the splint allowed for the most efficient distribution of material to achieve mechanical requirements while reducing the amount of material used. The reduction in used material leads to significant improvements in weight reduction and heat dissipation, which would improve breathability and less sweating for the patient, greatly increasing comfort for the duration of their recovery.

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Living the heart in three dimensions: applications of 3D printing in CHD

Cardiology in the Young ◽

10.1017/s1047951119000398 ◽

2019 ◽

Vol 29 (06) ◽

pp. 733-743 ◽

Cited By ~ 2

Author(s):

Mari Nieves Velasco Forte ◽

Tarique Hussain ◽

Arno Roest ◽

Gorka Gomez ◽

Monique Jongbloed ◽

...

Keyword(s):

3D Printing ◽

Heart Surgery ◽

Wide Spectrum ◽

Three Dimensional ◽

Structural Heart Disease ◽

Medical Personnel ◽

Three Dimensions ◽

Patient Specific ◽

3D Printed

AbstractAdvances in biomedical engineering have led to three-dimensional (3D)-printed models being used for a broad range of different applications. Teaching medical personnel, communicating with patients and relatives, planning complex heart surgery, or designing new techniques for repair of CHD via cardiac catheterisation are now options available using patient-specific 3D-printed models. The management of CHD can be challenging owing to the wide spectrum of morphological conditions and the differences between patients. Direct visualisation and manipulation of the patients’ individual anatomy has opened new horizons in personalised treatment, providing the possibility of performing the whole procedure in vitro beforehand, thus anticipating complications and possible outcomes. In this review, we discuss the workflow to implement 3D printing in clinical practice, the imaging modalities used for anatomical segmentation, the applications of this emerging technique in patients with structural heart disease, and its limitations and future directions.

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The Role of 3D Printing in Medical Applications: A State of the Art

Journal of Healthcare Engineering ◽

10.1155/2019/5340616 ◽

2019 ◽

Vol 2019 ◽

pp. 1-10 ◽

Cited By ~ 48

Author(s):

Anna Aimar ◽

Augusto Palermo ◽

Bernardo Innocenti

Keyword(s):

3D Printing ◽

Three Dimensional ◽

Patient Specific ◽

Digital Information ◽

Medical Implants ◽

Medical Field ◽

3D Printed ◽

Pipe Dream ◽

Manufacturing Technologies

Three-dimensional (3D) printing refers to a number of manufacturing technologies that generate a physical model from digital information. Medical 3D printing was once an ambitious pipe dream. However, time and investment made it real. Nowadays, the 3D printing technology represents a big opportunity to help pharmaceutical and medical companies to create more specific drugs, enabling a rapid production of medical implants, and changing the way that doctors and surgeons plan procedures. Patient-specific 3D-printed anatomical models are becoming increasingly useful tools in today’s practice of precision medicine and for personalized treatments. In the future, 3D-printed implantable organs will probably be available, reducing the waiting lists and increasing the number of lives saved. Additive manufacturing for healthcare is still very much a work in progress, but it is already applied in many different ways in medical field that, already reeling under immense pressure with regards to optimal performance and reduced costs, will stand to gain unprecedented benefits from this good-as-gold technology. The goal of this analysis is to demonstrate by a deep research of the 3D-printing applications in medical field the usefulness and drawbacks and how powerful technology it is.

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Parameters Affecting the Mechanical Properties of Three-Dimensional (3D) Printed Carbon Fiber-Reinforced Polylactide Composites

Polymers ◽

10.3390/polym12112456 ◽

2020 ◽

Vol 12 (11) ◽

pp. 2456

Author(s):

Demei Lee ◽

Guan-Yu Wu

Keyword(s):

Mechanical Properties ◽

Carbon Fiber ◽

3D Printing ◽

Three Dimensional ◽

Fused Deposition Modelling ◽

Layer By Layer ◽

Fused Deposition ◽

Bed Temperature ◽

3D Printed ◽

The Impact

Three-dimensional (3D) printing is a manufacturing technology which creates three-dimensional objects layer-by-layer or drop-by-drop with minimal material waste. Despite the fact that 3D printing is a versatile and adaptable process and has advantages in establishing complex and net-shaped structures over conventional manufacturing methods, the challenge remains in identifying the optimal parameters for the 3D printing process. This study investigated the influence of processing parameters on the mechanical properties of Fused Deposition Modelling (FDM)-printed carbon fiber-filled polylactide (CFR-PLA) composites by employing an orthogonal array model. After printing, the tensile and impact strengths of the printed composites were measured, and the effects of different parameters on these strengths were examined. The experimental results indicate that 3D-printed CFR-PLA showed a rougher surface morphology than virgin PLA. For the variables selected in this analysis, bed temperature was identified as the most influential parameter on the tensile strength of CFR-PLA-printed parts, while bed temperature and print orientation were the key parameters affecting the impact strengths of printed composites. The 45° orientation printed parts also showed superior mechanical strengths than the 90° printed parts.

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A review and guide to creating patient specific 3D printed anatomical models from MRI for benign gynecologic surgery

3D Printing in Medicine ◽

10.1186/s41205-021-00107-7 ◽

2021 ◽

Vol 7 (1) ◽

Author(s):

Teresa E. Flaxman ◽

Carly M. Cooke ◽

Olivier X. Miguel ◽

Adnan M. Sheikh ◽

Sukhbir S. Singh

Keyword(s):

3D Printing ◽

Clinical Benefit ◽

Three Dimensional ◽

Uterine Fibroids ◽

3D Models ◽

Gynecologic Surgery ◽

Patient Specific ◽

Mr Images ◽

Adjacent Structures ◽

3D Printed

Abstract Background Patient specific three-dimensional (3D) models can be derived from two-dimensional medical images, such as magnetic resonance (MR) images. 3D models have been shown to improve anatomical comprehension by providing more accurate assessments of anatomical volumes and better perspectives of structural orientations relative to adjacent structures. The clinical benefit of using patient specific 3D printed models have been highlighted in the fields of orthopaedics, cardiothoracics, and neurosurgery for the purpose of pre-surgical planning. However, reports on the clinical use of 3D printed models in the field of gynecology are limited. Main text This article aims to provide a brief overview of the principles of 3D printing and the steps required to derive patient-specific, anatomically accurate 3D printed models of gynecologic anatomy from MR images. Examples of 3D printed models for uterine fibroids and endometriosis are presented as well as a discussion on the barriers to clinical uptake and the future directions for 3D printing in the field of gynecological surgery. Conclusion Successful gynecologic surgery requires a thorough understanding of the patient’s anatomy and burden of disease. Future use of patient specific 3D printed models is encouraged so the clinical benefit can be better understood and evidence to support their use in standard of care can be provided.

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The use of three-dimensional anatomical patient-specific printed models in surgical clipping of intracranial aneurysm: A pilot study

Surgical Neurology International ◽

10.25259/sni_361_2020 ◽

2020 ◽

Vol 11 ◽

pp. 381

Author(s):

Moneer K. Faraj ◽

Samer S. Hoz ◽

Amjad J. Mohammad

Keyword(s):

3D Printing ◽

Teaching Hospital ◽

Three Dimensional ◽

3D Models ◽

Patient Specific ◽

Anterior Communicating Artery ◽

Parent Vessel ◽

Microsurgical Clipping ◽

Valuable Adjunct ◽

3D Printed

Background: In the present study, we aim to develop simulation models based on computed tomography angiography images of intracranial aneurysms (IAs) and their parent vessels using three-dimensional (3D) printing technology. The study focuses on the value of these 3D models in presurgical planning and intraoperative navigation and ultimately their impact on patient outcomes. To the best of our knowledge, this is the first report of its kind from a war-torn country, like Iraq. Methods: This is a prospective study of a series of 11, consecutively enrolled, patients suffering from IAs for the period between February and September 2019. The study represents a collaboration between the two major neurosurgical centers in Baghdad/Iraq; Neurosciences Teaching Hospital and Neurosurgery Teaching Hospital. We analyzed the data of eleven patients with IAs treated by microsurgical clipping. These data include patient demographics, clinical, surgical, and outcomes along with the data of the 3D-printed replica used in these surgeries. All cases were operated on by one surgeon. Results: Our study included 11 patients, with a total of 11 aneurysms clipped. The mean age was 44 ± 8, with a median of 42.5 and a range of 35–61 years. About 60% of our patients were female with a female-to-male ratio of 1:5. About 60% of the aneurysms were located at the anterior communicating artery (Acom) while the remaining 40% were equally distributed between the posterior communicating and internal carotid arteries bifurcation. The standard pterional approach was followed in 50% of cases, whereas the other 50% of patients were treated through the lateral supraorbital approach. About 90% (n = 9) of the patients had a Glasgow Outcome Scale (GOS) of 5 and 10% had a GOS of 4. The 3D-printed models successfully replicated the aneurysm size, location, and relation to the parent vessel with 100% accuracy and were used for intraoperative guidance. The average production time was 24–48 h and the production cost was 10–20 US dollars. Conclusion: 3D printing is a promising technology that is rapidly penetrating the field of neurosurgery. In particular, the use of 3D-printed patient-matched, anatomically accurate replicas of the cerebral vascular tree is valuable adjunct to the microsurgical clipping of IAs, and our study conclusions support this concept. However, both the feasibility and clinical utility of 3D printing remain the subject of much, ongoing investigations.

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3D Reconstruction Role in Surgical Treatment of Sinonasal Tumours

Revista de Chimie ◽

10.37358/rc.18.6.6345 ◽

2018 ◽

Vol 69 (6) ◽

pp. 1455-1457

Author(s):

Dragos Octavian Palade ◽

Bogdan Mihail Cobzeanu ◽

Petronela Zaharia ◽

Marius Dabija

Keyword(s):

3D Printing ◽

Three Dimensional ◽

Patient Specific ◽

Three Dimensional Printing ◽

Great Progress ◽

3D Printed ◽

Medical Modeling ◽

Dimensional Printing ◽

Tissue Defects

Three-dimensional printing has numerous applications and has gained much interest in the medical world. The constantly improving quality of 3D-printing applications has contributed to their increased use on patients. Nowadays, 3D printing is very well integrated in the surgical practice and research. Also, the field of head and neck reconstructive surgery is constantly evolving because of the three-dimensional printing, a technology which can be widely used in a variety of situations such as reconstruction of tissue defects, surgical planning, medical modeling and prosthesis. By using 3D printing into tissue engineering and materials, it may be possible for otolaryngologists to implant 3D printed functional grafts into patients and will also provide a rapid production of personalized patient-specific devices. Advances in 3D printed implants and future tissue-engineered constructs will bring great progress to the field of otorhinolaryngology.

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Is Preoperative Planning for Hip Surgery Using Three-Dimensional Printed Models Associated with Improved Intra- and Postoperative Outcomes? A Systematic Review

The Journal of Hip Surgery ◽

10.1055/s-0039-1693001 ◽

2019 ◽

Vol 03 (03) ◽

pp. 151-160

Author(s):

Michael J. Mosca ◽

Pablo Castañeda

Keyword(s):

3D Printing ◽

Clinical Outcomes ◽

Preoperative Planning ◽

Three Dimensional ◽

Postoperative Outcomes ◽

Hip Surgery ◽

Patient Specific ◽

Original Research ◽

Surgical Guides ◽

3D Printed

AbstractUse of three-dimensional (3D) printed models for preoperative planning, patient-specific surgical guides, and implants in orthopaedic surgery is a burgeoning technology. It has not been established if 3D-printed models for preoperative planning are associated with improved clinical outcomes or if they are cost-effective for hip surgeries including total hip arthroplasty (THA), periacetabular osteotomy (PAO), proximal femoral osteotomy (PFO), and/or hip fractures. The purpose of this study was to conduct a systematic search and literature review to determine if preoperative planning for hip surgery using 3D-printed models was associated with improved intra- and postoperative outcomes. Specific aims were to determine the (1) types of applications and studies conducted, (2) types of 3D printing/materials used, (3) specific outcomes evaluated, (4) efficacy of 3D printing in planning for hip surgery, and (5) limitations of current research. The authors searched Medline, Embase, Cochrane Database of Systematic Reviews, CINAHL, and PubMed from inception through July 2017. Original research publications were included if the primary purpose was to evaluate 3D-printed models' ability to assist with the planning of hip surgeries. Papers were excluded if they were reviews, abstracts, and not available in English, their models were not patient-specific, or their research did not evaluate surgery of the acetabulofemoral joint or pelvis. Of the 3,369 unique papers identified, 21 met inclusion criteria after full-text review. Among the included studies, six evaluated 3D printing in THA, seven in PAO/PFO, and eight in fracture repairs/reconstruction. The research included nine case reports, three case series, one retrospective uncontrolled study, six prospective uncontrolled studies, and two prospective controlled studies. 3D printed models resulted in: reduced intraoperative improvisation, operating room time, blood loss/transfusions, improved positioning of plates/screws/implants, clinical scores, measures of realignment, and functional status. Recent innovations in 3D printing are promising but unproven to improve clinical outcomes in hip surgeries due to limitations of published research. This may impact utilization and reimbursement of 3D-printed models in hip surgery. Studies of resource utilization, cost-effectiveness, and controlled trials with standardized methods and clinical outcomes of relevance are needed.

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