Fused Deposition Modeling and Fabrication of a Three-dimensional Model in Maxillofacial Reconstruction

The utilization of customized three-dimentional (3D) models based on patient's computed tomography (CT) scan data and by assistance of additive manufacturing/rapid prototyping (AM/RP) techniques for 3D reconstruction is one of the applicable trends for reducing the errors and time saving during surgeries. In the present study, the methodology of the fabrication of a custom-made 3D model based on converting CT scan data to standard triangle language (STL) format for a 33-years old male patient who was suffering from an accident trauma was described. The 3D model of the patient’s skull was fabricated and applied in preoperative planning. It was used for designing a comprehensive plan for rehabilitation of the damaged orbit to restore the appearance and bone reconstruction of the patient. Before fabricating the model, the accuracy of protocols used in converting CT scan data into STL file was evaluated. Then, the model was fabricated by a fused deposition modeling (FDM) machine. Using this procedure led to a maximum of 1.4% difference between the virtual model in the software and the fabricated 3D model in the fracture site. The present technique reduced operation time significantly. In addition, following eight months from the operation, the treatment approach ensured the patient's fractures healing process.