3D printing in medicine最新文献

{"title":"Early stage prediction of bone regeneration using FEA and cell differentiation algorithms with 3D-printed PLA and PCL scaffolds: modeling and application to dorsal double-plating in distal radius fractures.","authors":"Hsuan Chih Liu, Ya-Han Chan, Shao-Fu Huang, Wei-Che Tsai, Yen Cheng, Chun-Li Lin","doi":"10.1186/s41205-025-00278-7","DOIUrl":"10.1186/s41205-025-00278-7","url":null,"abstract":"<p><p>This study introduces an advanced framework that integrates biphasic cell differentiation bone remodeling theory with finite element (FE) analysis and multi-remodeling simulation to evaluate the performance of 3D-printed biodegradable scaffolds for bone defect repair. The program incorporates a time-dependent cell differentiation stimulus (S), accounting for fluid-phase shear stress and solid-phase shear strain, to dynamically predict bone cell behavior. The study focuses on polylactic acid (PLA) and polycaprolactone (PCL) scaffolds with diamond (DU) and random (YM) lattice designs, applied to a dorsal double-plating (DDP) fixation model for distal radius fractures. Material testing reveals that PLA provides higher rigidity and strength, while PCL offers superior ductility. Mechanical strength tests confirm the superior performance of DU lattice structures under compression, shear, and torsion forces. The bone remodeling program, applied to 36 model combinations of fracture gaps, materials, and lattice designs, computes the total percentage of cell differentiation (TPCD), identifying scaffold material as the key factor, with PLA significantly enhancing TPCD values. Biomechanical analysis after 50 remodeling iterations in a 5.4 mm fracture gap shows that the PLA + DU scaffold reduces displacement by 35%/39%/75%, bone stress by 19%/16%/67%, and fixation plate stress by 77%/66%/93% under axial/bending/torsion loads, respectively, compared to the PCL + YM scaffold. This study highlights the critical role of dynamic remodeling programs in optimizing scaffold material properties and lattice architectures, establishing a robust platform for patient-specific bone repair solutions in regenerative medicine.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":"11 1","pages":"30"},"PeriodicalIF":3.2,"publicationDate":"2025-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12177956/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144327927","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A comparative study between CT angiography and flow parameters in hemodynamic phantom of carotid stenosis evaluated by duplex sonography.","authors":"Anna Seidlová, Norbert Svoboda, Richard Voldřich, Petra Kešnerová, Roman Matějka, David Pakizer, David Školoudík, David Netuka","doi":"10.1186/s41205-025-00271-0","DOIUrl":"10.1186/s41205-025-00271-0","url":null,"abstract":"<p><strong>Background: </strong>The use of 3D-printed hemodynamic phantom of a stenotic carotid artery has not been extensively investigated. Our study aims to address this gap by exploring the correlation between CTA and flow parameters in hemodynamic phantom.</p><p><strong>Methods: </strong>Patients with carotid stenosis were included in a prospective study. A realistic phantoms of carotid artery stenoses were 3D-printed based on CT angiography. Stenosis severity and hemodynamic flow parameters in the phantom evaluated using duplex sonography were correlated with CTA. The primary outcome was to compare the evaluation of the percentage of stenosis based on the measurement of diameter reduction and area reduction of the carotid artery among CTA, a 3D model constructed from CTA data, and ultrasound measurement of stenosis percentage within the 3D printed phantom. The secondary outcome was to determine whether the percentage of stenosis measured by ultrasound in B-mode or ultrasound-measured flow velocities (PSV, EDV) better correlates with the stenosis percentage derived from CTA and the phantom.</p><p><strong>Results: </strong>The study included 95 subjects (average age 71 years, 75% male) with carotid stenosis, 39% were symptomatic. Significant correlations were found between ultrasound B-Mode findings on the phantom and CTA, with the strongest correlations for area reduction (Spearman r = 0.615, p < 0.0001) and diameter reduction (Spearman r = 0.465, p < 0.0001). The most robust correlation between PSV and EDV in stenosis and the percentage of stenosis was identified between PSV in stenosis and the percentage of stenosis by diameter reduction, as evaluated through ultrasound. The Spearman correlation coefficient revealed a relatively strong correlation, with a value of r = 0.444 (p < 0.0001), and the Kendall Tau correlation coefficient also demonstrated significance, with a value of r = 0.302 (p < 0.0001).</p><p><strong>Conclusions: </strong>A significant correlation between CTA and duplex sonography measurements on the carotid phantom was demostrated, suggesting the potential utilization of the phantom in testing hemodynamic parameters of carotid stenosis.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":"11 1","pages":"29"},"PeriodicalIF":3.2,"publicationDate":"2025-06-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12172251/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144318851","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Challenges of access to cadavers in low- and middle-income countries (LMIC) for undergraduate medical teaching: a review and potential solutions in the form of 3D printed replicas.","authors":"Paul G McMenamin, Lucy F Costello, Michelle R Quayle, John F Bertram, Aboubacar Kaka, Nakapi Tefuarani, Justin W Adams","doi":"10.1186/s41205-025-00277-8","DOIUrl":"10.1186/s41205-025-00277-8","url":null,"abstract":"<p><p>The inequity of resources available for learning human anatomy, one of the basic sciences underpinning a medical or allied health training, between low- and high-income countries is stark. Many Low Middle-Income Countries (LMIC) have no access to cadavers for the study of human anatomy. In this review we try to highlight the status of anatomy education especially with regards to the barriers to accessing cadavers such as cost, local laws and regulations, religious beliefs and cultural mores. Many of these barriers are more acute in LMIC. We discuss possible solutions to the shortage of cadaver material and specifically we detail 3 case studies in which authors from high income countries can assist colleagues in LMIC institutions teach anatomy using 3D printed replicas of human dissections. The case for this assistance is made and its practical application together with its evaluation is presented. The case studies include medical schools in Liberia, Fiji and Papua New Guinea. The outcomes suggest this model could be expanded to other countries who lack the economic resources to adequately provide learning materials for undergraduate students in medicine and other allied health disciplines.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":"11 1","pages":"28"},"PeriodicalIF":3.2,"publicationDate":"2025-06-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12167578/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144295472","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"3D printed vitamin D impregnated catheters for magnetic resonance-guided interventions: proof of concept and imaging characteristics.","authors":"Liam O Cunningham, Aravinda Ganapathy, Cihat Eldeniz, Jeffery A Weisman, Kevin E Lindsay, Udayabhanu Jammalamadaka, Karthik Tappa, Amber Salter, Hongyu An, Pamela K Woodard, David H Ballard","doi":"10.1186/s41205-025-00273-y","DOIUrl":"10.1186/s41205-025-00273-y","url":null,"abstract":"<p><strong>Background: </strong>Catheters used for magnetic resonance (MR)-guided interventions require intra-catheter coils and often produce artifacts. This study aimed to fabricate 3D-printed catheters impregnated with vitamin D solution to allow for optimal visualization during MR-guided procedures.</p><p><strong>Methods: </strong>3D printing was used to fabricate catheters impregnated with vitamin D solution. Computer-aided design files were generated for a size 18 French catheter prototype with a compartment for vitamin D solution to be manually introduced into the catheter's lumen and sealed via thermoplastic welding. Polylactic acid (PLA) bioplastic was 3D printed into filaments via material extrusion (FDM^®, Stratasys, Eden Prairie, MN) on a 5th generation Replicator 3D printer (MakerBot). Three different forms of vitamin D were used, cholecalciferol, ergocalciferol, and calcitriol, and 0.9% normal saline served as a control. Three prints of each catheter type were fabricated and scanned using a 1.5 T MR whole body scanner (Avanto, Siemens Healthcare) inside a small flex loop surface radiofrequency (RF) coil. A 3D gradient recalled echo (GRE) sequence was used with the following acquisition parameters: 4.52/11 ms TE/TR, 15° flip angle, 256 × 256 matrix with 0.5 mm × 0.5 mm in-plane resolution, 24 coronal slabs, 2 mm thickness, and 140 Hz receiver bandwidth. Three averages were used to improve the signal-to-noise ratio (SNR). The GRE sequence was run with 4 different flip angles: 3°, 15°, 30°, and 45° to perform T1 mapping.</p><p><strong>Results: </strong>All 3D-printed catheters impregnated with vitamin D produced a signal on MR. SNR for vitamin D catheters was similar across the various forms of vitamin D: mean SNRs for 100% cholecalciferol, ergocalciferol, and calcitriol were 138, 139, and 130. Mean SNR and contrast-to-noise ratio (CNR) for vitamin D catheters were significantly higher than the control saline catheter (p < 0.001, for both SNR and CNR). T1 values were lower in vitamin D-impregnated catheters compared to the saline control (228 ± 67 ms and 3371 ± 493 ms, respectively; p < 0.0001), indicating a better signal.</p><p><strong>Conclusions: </strong>3D printing of catheters impregnated with vitamin D is feasible and can potentially optimize MR-guided procedures.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":"11 1","pages":"27"},"PeriodicalIF":3.2,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12164080/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144287387","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhancing skull base tumor management: the combination of 3D printing technology and endoscopic surgical techniques.","authors":"Xiao Li, Peng Gao, Angsi Liu, Fuxing Zuo, Ke Hu, Yang Wang, Haiyan Li, Jianxin Kong, Xueji Li","doi":"10.1186/s41205-025-00275-w","DOIUrl":"10.1186/s41205-025-00275-w","url":null,"abstract":"<p><strong>Object: </strong>3D printing technology stands as a transformative force in medicine, offering outstanding precision and personalization in surgical planning, patient education, and the development of anatomical models for complex procedures. This paper aims to explore the application experiences of 3D printing in endoscopic skull base tumor surgeries, evaluating the impact and effectiveness of 3D-printed models in enhancing both surgical simulations and anatomical learning in the field of neurosurgery for skull base tumors.</p><p><strong>Method: </strong>From October 2015 to March 2019, our institution enrolled five patients for whom individualized 3D-printed models were created, utilizing different printing techniques and materials. These models served a critical role in preoperatively determining the most effective surgical approaches. Additionally, they were instrumental in facilitating endoscopic surgery simulations and enhancing anatomical education. To assess the utility of these 3D models, nine neurosurgeons from our institution were surveyed using the Likert scale questionnaire, providing valuable insights into the effectiveness of 3D printing in clinical applications of neurosurgery.</p><p><strong>Result: </strong>Our team successfully printed five complex skull base tumor models using 3D printing technology, which significantly improved the outcome of skull base tumor diagnosis and treatment. An evaluation of the Likert scores revealed that model 4, crafted using mixed photosensitive resin, was particularly effective for surgical simulation and anatomical education. The mean (standard deviation, SD) 3D printing time is 16.3 (5.54) hours, and the mean (SD) printing cost is 4,500 (1132.88) RMB, demonstrating the efficiency of this approach.</p><p><strong>Conclusion: </strong>3D printing technology emerges as a highly valuable asset in the realm of endoscopic surgery for skull base tumors. Its rapid production turnaround allows for urgent surgical preparation needs. Additionally, this technology optimizes the learning curve for clinical pathological anatomy and endoscopic surgery. This combination advances surgical practices and training, particularly in the challenging domain of skull base neurosurgery.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":"11 1","pages":"26"},"PeriodicalIF":3.2,"publicationDate":"2025-06-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12160388/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144276828","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Contribution of 3D visualization and printing in teaching lung segments anatomy.","authors":"Gabrielle Drevet, Valentin Soldea, Sylvain Gouttard, Melia Virely, Jean-Michel Maury, François Tronc","doi":"10.1186/s41205-025-00272-z","DOIUrl":"10.1186/s41205-025-00272-z","url":null,"abstract":"<p><strong>Background: </strong>The knowledge and understanding of the anatomy of lung segments is of great importance while segmentectomies are increasingly performed. To introduce new technologies and tools in anatomy teaching could help students to improve their skills.</p><p><strong>Methods: </strong>Students participants (n = 16) were divided into 3 groups: traditional (n = 5), 3D visualization (n = 5) and 3D printing group (n = 6). Each student took a pre- and post-test exam. The traditional teaching group had lessons using 2D anatomical drawings, the 3D visualization group had lessons using a dedicated software allowing anatomical 3D reconstructions and the 3D printing group had lessons using 3D printed anatomical models.</p><p><strong>Results: </strong>Students of the whole cohort had significant better scores at the post test (mean score = 14.2) compared to the pretest (mean score = 7.9) (p = 0.0011). In the traditional and 3D printing groups, students had significant better scores in the post-test (mean scores = 17.7 and 14.2 respectively) than in the pre-test (mean scores = 8.2 and 7.5; p = 0.0247 and p = 0.0003 respectively). There was no significant difference between the pre and post-test scores for the 3D visualization group (mean score = 8.2 and 11.7 respectively) (p = 0.4347).</p><p><strong>Conclusions: </strong>The knowledge of lung segment anatomy is poor among our medical students. Both traditional and 3D-printed teaching was shown effective. The contribution of 3D printed models would probably improve anatomy teaching among medical students. The introduction of this technology is instinctive and easy to use for both students and teachers. Furthermore, this technique was not particularly expensive to set up.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":"11 1","pages":"25"},"PeriodicalIF":3.2,"publicationDate":"2025-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12147242/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144251067","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Printing outsourced orthognathic surgical splints in-house: a dimensional verification process for point-of-care printing.","authors":"Talal Beidas, Luther Light, Caroline Carrico, Shayne Kondor, Prasanth Ravi, Yotom A Rabinowitz","doi":"10.1186/s41205-025-00276-9","DOIUrl":"10.1186/s41205-025-00276-9","url":null,"abstract":"<p><strong>Background: </strong>Both outsourcing virtual surgery planning and 3D printed splint fabrication have become the standard in the field of orthognathic surgery. In-house (IH) adaptation of these presurgical operations requires compliance with regulatory bodies when designing and manufacturing medical-grade products. The purpose of this study is to evaluate the dimensional accuracy of IH 3D printed orthognathic surgical splints within a hybrid workflow for externally designed splints.</p><p><strong>Materials and methods: </strong>An in vitro study was conducted utilizing an outsourced (OS) orthognathic surgical splint file from a previously treated patient. The control group included the splint's original standard tessellation language (STL) file. Experimental groups included: splint (a) milled with zirconia, (b) 3D printed on a Phrozen 4 K (commercial printer), (c) 3D printed on Formlabs 3B+ (Formlabs 3B + have track record of having FDA cleared materials and workflows in dental applications and have potential materials that could be used for IH manufacturing for orthognathic splints upon further testing and FDA clearance). Surface area analysis was performed using 3-Matic (Materialise© Mimics Software) to generate root mean square (RMS) values between digital copies of the splints and their corresponding original STL files.</p><p><strong>Results: </strong>The RMS error in equipment processing and analysis was measured at 0.10 mm. Accounting for this error, the 3D-printed splints exhibited an average RMS of 0.20 mm for both the Formlabs 3B + and the Phrozen 4 K. No statistically significant difference was found between splints from different printers or replicas.</p><p><strong>Conclusion: </strong>This study presents a verification process for providers to verify the geometric stability and reproducibility of their IH-printed orthognathic splints (RMS 0.20 mm). Clinicians may find this study useful when crafting a regulatory-compliant process for the IH manufacturing of OS orthognathic surgery splints.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":"11 1","pages":"24"},"PeriodicalIF":3.2,"publicationDate":"2025-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12143043/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144236078","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Clinical case study on custom 3D printed collars for dropped head syndrome patients.","authors":"Abir Dutta, Jim Ashworth-Beaumont, Sanganagouda Patil, Kia Rezajooi, Deepak M Kalaskar","doi":"10.1186/s41205-025-00274-x","DOIUrl":"10.1186/s41205-025-00274-x","url":null,"abstract":"<p><strong>Background: </strong>Dropped Head Syndrome (DHS) is a neurological condition characterized by severe head and neck muscle atrophy, leading to difficulties in maintaining a straight gaze and experiencing severe neck pain during daily activities. Standard off-the-shelf cervical orthotic devices (Neck Collars) often fail to provide adequate support for patients with DHS. This feasibility study aimed to develop and implement a novel feedback-incorporated workflow for creating personalized 3D printed (Powder Bed Fusion) cervical orthotic devices for six DHS patients with varying pathologies.</p><p><strong>Case presentation: </strong>A tailored workflow was devised and executed to produce bespoke 3D printed cervical orthotic devices for 6 DHS patients. The effectiveness of the collars in supporting patients during activities and reducing neck pain was assessed quantitatively and qualitatively using validated patient support questionnaires, Neck Disability Index, Visual Analog Score for Neck Pain, Global Cervical Angles (GCA), and Vertical Chin Brow Angles (VCBA) before and after intervention. Various clinical and design parameters were analysed to evaluate the collars' efficacy in supporting patients and reducing neck pain. Patients exhibited an increase in GCA and a decrease in VCBA when using the collars as compared to their previous condition without those. The Visual Analog Score for Neck Pain decreased over the 6-month follow-up period, indicating positive implementation of the bespoke collars.</p><p><strong>Conclusion: </strong>The personalized design and functionality of the 3D printed collars significantly improved patients' quality of life, representing a significant advancement in rehabilitative and supportive healthcare interventions. This pilot study lays the groundwork for further large-scale cohort studies.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":"11 1","pages":"23"},"PeriodicalIF":3.2,"publicationDate":"2025-06-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12139371/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144227818","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Unperceived bronchial bleeding complications during percutaneous dilatational tracheotomy: a case report and 3D simulation.","authors":"Khalid Salem, Hendrik Drinhaus, Dominique Hart, Bernd W Böttiger, Andrea U Steinbicker, Bernhard Dorweiler, Fabian Dusse","doi":"10.1186/s41205-025-00270-1","DOIUrl":"10.1186/s41205-025-00270-1","url":null,"abstract":"<p><p>Percutaneous dilatational tracheostomy is an established technique for securing the airway in critically ill patients. One of the most common complications is bleeding around the incision or after injury to major vessels in anatomic proximity.We report a case in which a thrombocytopenic patient experienced life-threatening bleeding during the procedure at the bifurcation between segmental bronchus 9 and 10, apparently caused by an unrecognized guide wire-induced mucosal lesion. Immediate extensive bronchoscopy and hemostatic interventions were required to ensure oxygenation. To better illustrate this complication, a patient-specific (1:1) three-dimensional model of the patient's bronchial system was subsequently created using a 3D printer. In conclusion, 3d printing can help to visualize uncommon complications during intensive care interventions. It is recommended to advance the guide wire the guide wire only until the tracheal carina under bronchoscopic control.Word count: 135.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":"11 1","pages":"22"},"PeriodicalIF":3.2,"publicationDate":"2025-05-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12123887/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144188579","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Biomechanical design considerations of a 3D-printed tibiotalocalcaneal nail for ankle joint fusion.","authors":"Kin Weng Wong, Shao-Fu Huang, Skye Hsin-Hsien Yeh, Tai-Hua Yang, Cheng-Yi Liang, Chun-Li Lin","doi":"10.1186/s41205-025-00268-9","DOIUrl":"https://doi.org/10.1186/s41205-025-00268-9","url":null,"abstract":"<p><p>Tibiotalocalcaneal (TTC) arthrodesis treatment using intramedullary nails faces significant challenges due to inadequate bone integration and mechanical stability. This study developed a novel 3D-printed long titanium TTC intramedullary nail incorporating diamond lattice structures and differential thread leads to enhance biological fixation and compression. Four 3D-printed TTC nails (5 mm diameter, 70 mm length) with solid (TTC 1), lattice structure (TTC 2), lattice with longitudinal ribs (TTC 3), and lattice with both longitudinal and transverse ribs (TTC 4) were designed and manufactured. The lattice region featured a diamond array (70% porosity, 650 μm pore size, 1.2 mm unit length) with 2.5 mm thickness surrounding a 2.5 mm solid core. Static four-point bending tests assessed mechanical strength following ASTM F1264 protocols. Six skeletally mature Yorkshire pigs underwent TTC arthrodesis using TTC 1, 2, and 4 designs. Outcomes were evaluated using radiographic imaging and micro-CT analysis at 12 weeks post-surgery. All 3D-printed nails demonstrated acceptable precision with errors below 5% for straightness, circularity, and pitch distance. Mechanical testing revealed fracture strengths of 2387.33 ± 32.88 N, 435.00 ± 50.00 N, 849.17 ± 63.98 N, and 1133.67 ± 81.28 N for TTC 1-4, respectively. The differential thread design achieved significant compression ratios (81-82.5%) at fusion sites. Micro-CT analysis showed significantly higher bone formation in lattice designs (TTC 2: 145.37 ± 37.35 mm³, TTC 4: 137.81 ± 9.52 mm³) compared to the solid design (TTC 1: 28.085 ± 3.21 mm³). However, TTC 2 experienced two implant fractures, while TTC 4 maintained structural integrity while promoting substantial bone growth. This study concluded that titanium 3D printing technology can be applied for manufacturing long TTC intramedullary nails with surface lattice design but reinforcing ribs need to be added to provide enough mechanical strength.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":"11 1","pages":"21"},"PeriodicalIF":3.2,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC12063370/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144060510","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}