Svenja Jung, Maike Stummer, Christian König, Erdem Güresir, Dirk Winkler, Felix Arlt, Ronny Grunert
{"title":"Development of a new operative 3D printed template-cranioplasty-concept for performing craniotomy in the posterior cranial fossa and validation of the system using a 3D printed simulation model: a preclinical feasibility study.","authors":"Svenja Jung, Maike Stummer, Christian König, Erdem Güresir, Dirk Winkler, Felix Arlt, Ronny Grunert","doi":"10.1186/s41205-026-00332-y","DOIUrl":"10.1186/s41205-026-00332-y","url":null,"abstract":"<p><strong>Background: </strong>The retrosigmoid approach is a standard surgical route used for the treatment of various tumors and vascular lesions in the cerebellopontine angle. However, postoperative reconstruction of the surgical defect could remain challenging, particularly in cases requiring intraoperative extension. For this reason, a novel concept was developed to define the surgical approach and enable precise defect coverage using a patient-specific implant. This concept was designed to be patient-specific and realized through 3D printing.</p><p><strong>Methods: </strong>The developed 3D printed template-implant concept was designed to facilitate precise craniotomy. The template is used as a stencil and a surgical marker is applied to delineate the implant contours directly on the patient's skull. This outline subsequently serves as a guide for where to perform the craniotomy and defines its boundaries. The custom-fit implant replicates the template design and ensures complete coverage of the craniotomy defect, while allowing intraoperative adjustment if required. Preclinical testing was conducted on a 3D printed simulation model representing the posterior cranial fossa (surgical area). The novel concept was tested by nine senior and attending neurosurgeons from the University Hospital Leipzig. Bilateral craniotomies were performed using the template and subsequently closed with the implant. The fit of the implant was evaluated using CT scans. The time required for preparation, including craniotomy, as well as for post-procedure handling, including implant placement, was recorded.</p><p><strong>Results: </strong>The average gap of the new concept was 2.11 mm, which was significantly smaller than that of the current standard approach (5.52 mm) and showed lower variability. The entire procedure, including craniotomy and implant placement, took an average of 13 min and 20 s.</p><p><strong>Conclusion: </strong>The novel template-implant concept for retrosigmoid approaches improves defect coverage and reduces gap sizes. Furthermore, it demonstrates the potential of 3D printed patient-specific implants for more precise and predictable surgical procedures, although further studies are required to validate efficiency and clinical safety.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":" ","pages":""},"PeriodicalIF":3.1,"publicationDate":"2026-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13285088/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148273917","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}
B Sanz-Peña, M Suffo, L Galán-Romero, A Jiménez-Alba, V García-Alcántara, I Iglesias-Lozano, F Rodríguez-Peña
{"title":"Development and preliminary validation of a multidisciplinary 3D‑printed skull base model for endoscopic endonasal surgical training.","authors":"B Sanz-Peña, M Suffo, L Galán-Romero, A Jiménez-Alba, V García-Alcántara, I Iglesias-Lozano, F Rodríguez-Peña","doi":"10.1186/s41205-026-00318-w","DOIUrl":"10.1186/s41205-026-00318-w","url":null,"abstract":"<p><strong>Objective: </strong>The aim of the article is to present the development and application of a 3D-printed skull base model, which includes the internal carotid arteries, tumour and the optic nerve, to train neurosurgeons and ear, nose and throat (ENT) in performing the endonasal endoscopic approach (EEA). This procedure is challenging due to the proximity of critical structures such as nerves, blood vessels and brain.</p><p><strong>Methodology: </strong>The 3D model was generated using magnetic resonance imaging (MRI) and computed tomography (CT) scans, which provided detailed anatomical data. These scans were processed with 3D reconstruction software to accurately replicate the key areas, including the tumour and surrounding structures. Neurosurgery and ENT consultants and residents, practised the EEA using these printed models. After completing the procedures, participants filled out a questionnaire to evaluate the realism and reliability of the model by applying a statistical analysis appropriate to the study.</p><p><strong>Results: </strong>The participants reported that the 3D-printed models provided a highly realistic simulation of the anatomical structures involved in the EEA. The model was deemed effective in replicating the key areas of interest, allowing them to safely practise the procedure in a controlled environment. Our results show that in two days approximately and for less than 10€, the surgeon may have the opportunity to train the surgery after establishing the printing parameters. A strong positive correlation was found among these variables (p < 0.01), suggesting that those who found the model useful also perceived a greater clinical applicability and believed that the 3D-printed model could help improve their surgical skills.</p><p><strong>Conclusions: </strong>The study demonstrates that 3D-printed models based on MRI and CT scans offer a reliable and realistic method for surgical training. These models provide an essential tool for practising complex procedures, such as the EEA, improving the safety and effectiveness of surgical training and potentially enhancing patient outcomes.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":" ","pages":""},"PeriodicalIF":3.1,"publicationDate":"2026-05-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13244829/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147984459","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 and virtual kidney models as learning tools to improve anatomical and spatial understanding of renal tumors: a pilot educational study (Rein-3D print students - UroCCR 219).","authors":"Gaëlle Margue, Clément Michiels, Joffrey Sarrazin, Matthieu Faessel, Eva Jambon, Solène Ricard, Franck Bladou, Grégoire Robert, Jocelyn Sabatier, Frédéric Bos, Jean-Christophe Bernhard","doi":"10.1186/s41205-026-00319-9","DOIUrl":"10.1186/s41205-026-00319-9","url":null,"abstract":"<p><strong>Background: </strong>Radiological training is often underrepresented in medical education, despite its essential role in clinical practice. Innovations like 3D printing offer detailed anatomical models that enhance understanding. In kidney cancer management, imaging and tumor complexity scores are crucial. This study evaluated whether three-dimensional (3D) kidney models could improve medical students' anatomical and spatial understanding of renal tumors, as assessed through CT-based complexity scoring.</p><p><strong>Methods: </strong>Three kidney tumor cases of varying complexity were selected. CT scans were segmented using Synapse 3D<sup>®</sup> to create models printed with high-resolution, multi-material technology (Stratasys J750<sup>®</sup>). Twenty-three fifth-year medical students were randomized into three groups: CT-only, CT + 3D virtual model (3DV), and CT + 3D-printed model (3DP). Each group interpreted the same anonymized CT scans and completed questionnaires assessing complexity scores and anatomical understanding. Accuracy and time efficiency were compared across groups.</p><p><strong>Results: </strong>The 3DV and 3DP groups showed significantly greater accuracy in completing complexity scores (91% [IQR 82-91] and 91% [IQR 73-100]) than the CT-only group (73% [IQR 64-82], p < 0.05), reflecting improved spatial understanding of renal anatomy. Total scores and satisfaction were higher in 3D groups, with students endorsing the educational value of both model types. Time to completion was shorter in 3D groups (3DV: 9.4 min ± 4.7; 3DP: 7.1 min ± 3.5) versus CT-only (11 min ± 5.3, p < 0.05). Total scores and satisfaction were higher in 3D groups, with students endorsing the educational value of both model types.</p><p><strong>Conclusion: </strong>3D-printed and virtual kidney models improved students' spatial understanding and task performance in renal tumor complexity assessment, reflecting enhanced anatomical comprehension rather than pure CT interpretation skills. Virtual models, offering similar educational benefits at lower cost, may be especially valuable for integration into medical curricula.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":" ","pages":""},"PeriodicalIF":3.1,"publicationDate":"2026-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13188362/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147950305","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":"The psychological impact of using 3D printing and imaging technology for patient education: a scoping review.","authors":"Kayleigh Maxwell, Steve Leung, Gozde Ozakinci","doi":"10.1186/s41205-026-00327-9","DOIUrl":"10.1186/s41205-026-00327-9","url":null,"abstract":"<p><strong>Background: </strong>The way in which patient education is delivered during clinical consultations can have an impact on cognitive and emotional outcomes in patients. 3D printing and imaging can be used in patient education to improve understanding of the information and satisfaction with care. This scoping review sought to explore the psychological impact of using 3D models in patient education.</p><p><strong>Methods: </strong>Searches were conducted in PsycINFO, PsycARTICLES, PubMed, Medline and CINAHL. Levac et al.'s enhanced version of Arksey & O'Malley's methodological framework for conducting scoping reviews, and the PRISMA-ScR, were used to guide the screening and identification of relevant studies. Studies were included if they investigated the effect of using 3D models in patient education and explored psychological outcomes. Both quantitative and qualitative research were included.</p><p><strong>Results: </strong>Eleven studies were included in the review, including 2 qualitative studies. 3D models were most often used in educational consultations preceding a surgical procedure (n = 9). Psychological outcomes assessed were anxiety, quality of life, distress relief, and decisional conflict. The results were mixed, showing that using 3D models can have a positive as well as negative effect on psychological outcomes such as fear and disempowerment.</p><p><strong>Conclusions: </strong>Using 3D models in patient education has the potential to improve patient anxiety and other psychological outcomes. However, more research is required to identify which patients and types of consultations 3D models are most useful for. For example, appointments involving important decision-making may benefit from the inclusion of 3D models. It is also essential to consider the communicative approach of the healthcare professional in the delivery of patient education with 3D models, as this factor is key to the outcomes of shared decision-making.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":" ","pages":""},"PeriodicalIF":3.1,"publicationDate":"2026-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13185390/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147950316","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}
Aniol Bosch, Pauline Champion, Joaquim Ciurana, Antonio J Guerra
{"title":"Additively manufactured reinforced polymeric stents for peripheral artery disease: design, manufacture and performance evaluation.","authors":"Aniol Bosch, Pauline Champion, Joaquim Ciurana, Antonio J Guerra","doi":"10.1186/s41205-026-00328-8","DOIUrl":"10.1186/s41205-026-00328-8","url":null,"abstract":"<p><p>Stent failure in the peripheral arterial system remains a major clinical challenge due to high mechanical demands caused by limb movement. Unlike coronary arteries, below-the-knee vessels are exposed to continuous flexion, torsion and axial movement, increasing the risk of structural failure, stent collapse, fracture or migration. Due to their tuneable mechanical properties, polymeric stents enabled by advanced additive manufacturing emerge as a potential candidate to overcome the current limitations of metallic stents. This study examines whether polymeric stents made with the ST3DT process and reinforced photoresin can endure all phases of manufacturing and deployment - including printing, rinsing, post-curing, crimping, and sterilisation - while retaining suitable mechanical properties for vascular use. Nine different stent geometries were produced by varying strut angle and printing feedrate, thus achieving different strut profiles. Curing was assessed by DSC and FTIR and mechanical properties were evaluated with radial and axial compressions tests, three-point bending and crimping. Finally, a CT-scan was performed to analyse radiopacity of reinforced polymeric stents with promising results. The findings indicated that although decreasing strut angles and reducing printing speeds led to better mechanical performance, they also made the crimping process more challenging. Two stents were selected with a balance of all criteria to continue the development of novel photopolymerised polymeric stents.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":" ","pages":""},"PeriodicalIF":3.1,"publicationDate":"2026-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13227657/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147876840","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}
Renaat Coopman, Pieter Devolder, Constantijn Bogaert, Mauranne Lievens, Matthias Ureel, Benjamin Denoiseux, Kirsten Colpaert, Sabrina Commeyne, Johan Decruyenaere, Pieter De Backer, Tom Goffin, Christiaan Polet, Niki Rashidian, Katya Van Driessche, Erik Van Laecke, Wim Van Paepegem, Charles Van Praet, Wim Van Biesen, Geert Villeirs, Peter De Paepe, Piet Hoebeke, Frank Vermassen
{"title":"A step-by-step guide for implementation of virtual surgical applications and patient data centralization: practical experience and lessons learned.","authors":"Renaat Coopman, Pieter Devolder, Constantijn Bogaert, Mauranne Lievens, Matthias Ureel, Benjamin Denoiseux, Kirsten Colpaert, Sabrina Commeyne, Johan Decruyenaere, Pieter De Backer, Tom Goffin, Christiaan Polet, Niki Rashidian, Katya Van Driessche, Erik Van Laecke, Wim Van Paepegem, Charles Van Praet, Wim Van Biesen, Geert Villeirs, Peter De Paepe, Piet Hoebeke, Frank Vermassen","doi":"10.1186/s41205-026-00326-w","DOIUrl":"10.1186/s41205-026-00326-w","url":null,"abstract":"<p><strong>Background: </strong>The expansion of digitalization in the pre-, intra- and post-operative surgical phases allow the development and integration of advanced technologies such as virtual surgical planning (VSP), additive manufacturing (AM), augmented reality (AR) and virtual reality (VR) in surgical workflows, all aiming to improve the surgical precision and efficiency. However, their implementation in clinical practice leads to novel organizational challenges, such as excessive costs, inefficiencies in the use of hard- and software and availability, and the coordination of the required highly specific expertise and skill of different employees with backgrounds in different domains.</p><p><strong>Aim: </strong>We aim to provide a practical step-by-step overview of how a centralized platform within academic hospitals can solve practical and organizational problems concerning surgical digitalization.</p><p><strong>Methods: </strong>A bottom-up approach was used to ensure engagement from all stakeholders within the hospital. Hereto, a small core group identified all potential stakeholders deemed essential for a successful implementation of a centralized platform. These stakeholders were then initially approached separately by the core group and then brought together in multiple focus groups to discuss action points, identify essential components and find solutions for emerging barriers.</p><p><strong>Results: </strong>The implementation focused on 5 essential points: (1) medical imaging & segmentation process; (2) centralized Central Processing Unit (CPU) and Graphical Processing Unit (GPU) capacity with guaranteed continued collaboration with Department of Information and Communication Technologies (ICT); (3) medical device and in-house AM dealing with the production and sterilization of three dimensional (3D)-printed models; (4) Implementation of CPSD within the operating room; (5) External connection and collaboration with industry and other academic centres aimed to support interventional medical digitalization and the implementation of other innovative medical technologies. The protocol focuses on key aspects, including identifying existing innovations, naming prevailing challenges and formulating effective solutions.</p><p><strong>Conclusion: </strong>Centralizing digitalization in the hospital streamlines workflows, enabling faster processing and improved multidisciplinary collaboration. Success depends on coordinated input from medical, technical, and legal experts. The resulting platform fosters ongoing innovation while staying compliant and adaptable.</p><p><strong>Clinical trail number: </strong>Not applicable.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":" ","pages":""},"PeriodicalIF":3.1,"publicationDate":"2026-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13390418/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147846701","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}
Jose Carlos Villalobos-Lizardi, Shi-Joon Yoo, Brandon Peel, Francesco Bertelli, Andreea Dragulescu, Nick Arbic, David Barron, Osami Honjo, Christopher Haller, Carmel Daskalo, Luc Mertens, Israel Valverde
{"title":"Feasibility of 3D echocardiography-CT/CMR fusion to create atrioventricular valve-integrated 3D printed heart models in complex congenital heart disease: greater incremental benefit for surgeons than cardiac imagers.","authors":"Jose Carlos Villalobos-Lizardi, Shi-Joon Yoo, Brandon Peel, Francesco Bertelli, Andreea Dragulescu, Nick Arbic, David Barron, Osami Honjo, Christopher Haller, Carmel Daskalo, Luc Mertens, Israel Valverde","doi":"10.1186/s41205-026-00324-y","DOIUrl":"10.1186/s41205-026-00324-y","url":null,"abstract":"<p><strong>Background: </strong>Given the established and reproducible benefit of 3D-printed models in complex congenital heart disease (CHD) surgical planning, the focus has shifted from validating their utility to refining anatomical fidelity through enhanced imaging integration. The purpose of this study is to evaluate the perceived clinical utility of multimodality fusion 3D-printed cardiac models and to determine whether inclusion of valve structures confers incremental benefit over conventional single-modality 3D models in enhancing anatomical understanding and preoperative surgical planning among pediatric cardiac surgeons and imaging cardiologists in complex CHD.</p><p><strong>Methods: </strong>In this feasibility study, multimodality fusion 3D models were successfully generated by integrating cross-sectional imaging (cardiac computed tomography and magnetic resonance) with 3D echocardiographic datasets to reproduce atrioventricular valve apparatus and subvalvular structures in 10 pediatric patients with complex CHD. Ten faculty members (7 pediatric cardiologists with advanced imaging expertise and 3 pediatric cardiothoracic surgeons) evaluated 10 patient-specific models using a structured Likert questionnaire.</p><p><strong>Results: </strong>Surgeons assigned significantly higher ratings than imagers for anatomical understanding (median 5 vs 4; p = 0.002) and surgical planning (p < 0.001). Participants agreed that multimodality models are most valuable in complex congenital heart disease, particularly in cases requiring ventricular septal defect patching or intraventricular baffle repair involving the subvalvular apparatus.</p><p><strong>Conclusion: </strong>Multimodality imaging fusion for 3D printing is technically feasible and produces high-quality models with strong intraoperative correlation. Incorporation of atrioventricular valve anatomy provides meaningful incremental benefit-particularly for surgeons-enhancing operative planning in complex CHD.</p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":" ","pages":""},"PeriodicalIF":3.1,"publicationDate":"2026-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13214205/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147846651","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}
Neha Sharma, Jokin Zubizarreta Oteiza, Daniel Seiler, Sead Abazi, Lukas B Seifert, Michel Roethlisberger, Raphael Guzman, Florian M Thieringer
{"title":"Clinical implementation of an EU MDR-compliant point-of-care manufacturing framework for patient-specific 3D-printed PEEK implants in craniomaxillofacial reconstruction.","authors":"Neha Sharma, Jokin Zubizarreta Oteiza, Daniel Seiler, Sead Abazi, Lukas B Seifert, Michel Roethlisberger, Raphael Guzman, Florian M Thieringer","doi":"10.1186/s41205-026-00325-x","DOIUrl":"10.1186/s41205-026-00325-x","url":null,"abstract":"<p><p>BACKGROUND: Point-of-care (POC) three-dimensional (3D) printing of medical devices presents a paradigm shift in personalized medicine, yet clinical implementation of polyetheretherketone (PEEK) implants remains limited by regulatory, technical, and quality assurance challenges. Traditional external manufacturing timelines of 2–6 weeks constrain immediate reconstruction capabilities, particularly in trauma and oncologic cases requiring rapid intervention. Structured frameworks enabling MDR-compliant hospital-based production of implantable devices remain limited in the literature. METHODS: We implemented a comprehensive European Union Medical Device Regulation (EU MDR) 2017/745 Article 5(5)-compliant POC manufacturing framework incorporating an electronic quality management system aligned with ISO 13,485, a manufacturing execution system enabling end-to-end device traceability, risk management, process validation, biocompatibility evaluation, and integrated post-market surveillance. Medical-grade PEEK was processed using validated high-temperature specialised material extrusion 3D printers. RESULTS: Representative clinical applications of the EU MDR-compliant point-of-care manufacturing framework are illustrated in two anatomical contexts: (1) a POC 3D-printed PEEK cranial implant and (2) a POC 3D-printed PEEK facial implant. Manufacturing turnaround from image acquisition to sterile delivery was operationally achievable within 3–5 days. The patient-matched implants demonstrated accurate anatomical fit without intraoperative modification, with no major device-related complications observed. The framework has supported the production of over 40 + POC 3D-printed PEEK implants at the index institution and has since been adopted at multiple European centres, demonstrating transferability beyond the index case series. CONCLUSIONS: This work describes a validated EU MDR Article 5(5)-compliant framework for hospital-based production of patient-matched 3D-printed PEEK implants, demonstrated across cranial and facial reconstruction. Early clinical results support safety and feasibility, with end-to-end manufacturing achievable within a week, enabling flexible surgical planning. The framework provides a replicable pathway for regulated POC implant production, with multi-centre adoption and long-term outcome surveillance as critical next steps. </p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":" ","pages":""},"PeriodicalIF":3.1,"publicationDate":"2026-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13169556/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147790484","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}
Jakub Szary, Małgorzata Kowalczyk, Mateusz Zwierzycki, Piotr Knysak, Anna Nowak, Katarzyna Janczak, Cyprian Kornacki, Marcin Domżalski
{"title":"Optimizing the design and production of custom 3D-printed knee orthoses.","authors":"Jakub Szary, Małgorzata Kowalczyk, Mateusz Zwierzycki, Piotr Knysak, Anna Nowak, Katarzyna Janczak, Cyprian Kornacki, Marcin Domżalski","doi":"10.1186/s41205-026-00323-z","DOIUrl":"10.1186/s41205-026-00323-z","url":null,"abstract":"<p><p>BACKGROUND: Traditional methods for producing custom-made orthoses are often time-consuming, labor-intensive, and reliant on manual processes, which limit both scalability and the degree of individualization. The development of 3D scanning technologies, computer-aided design (CAD), and additive manufacturing offers a promising alternative enabling patient-specific solutions with greater precision, speed, and efficiency. This study aimed to create an algorithm for automating the design process of personalized knee orthoses based on 3D scanning and intended for 3D printing production. METHODS: A parametric modeling workflow was developed in the Rhino environment using the Grasshopper plug-in to streamline personalized knee orthoses creation. The process began with acquiring high-quality 3D scans using Structure Sensor Mark II scanner mounted on an iPad with 3DsizeMe software. The parametric algorithm was transformed into an autonomous Rhino plug-in using C# language and RhinoCommon API. As part of Post-Market Clinical Follow-up (PMCF), three participants with knee joint disorders used orthoses for one month. Assessment used a 5-point scale (1 = poor, 5 = excellent). Personalized orthoses were manufactured using powder-bed fusion technology with PA11 CF nylon powder reinforced with carbon fibers. RESULTS: Design time was reduced from approximately 8 h to 10,3 ± 1,4 min. In Grasshopper prototype phase, average design time was 26,7 ± 4,5 min. Following the implementation of the Rhino plug-in, the design time was further reduced to approximately 10 min. The tool was shown to meet user requirements and fulfill its intended purpose. All three PMCF participants rated orthoses positively, reporting high comfort, effective stabilization, increased physical activity, and overall satisfaction with functionality and appearance. Participants P1 and P2 noted a large increase in physical activity, with P1 indicating pain reduction that increased mobility. CONCLUSIONS: This study demonstrates that the combined use of Rhino and Grasshopper provides an effective platform for parametric design of personalized knee orthoses based on patient-specific 3D scans. The workflow reduced design time to approximately 10,3 ± 1,4 min, highlighting potential for routine clinical applications. This reduction is economically significant, lowering labor costs and implementation thresholds for personalized orthotic solutions in clinical practice. </p>","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":" ","pages":""},"PeriodicalIF":3.1,"publicationDate":"2026-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13169548/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147730786","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 novel method for the creation of a patient-specific realistic model of hypertrophic cardiomyopathy for surgical myectomy simulation.","authors":"Sylvana García-Rodríguez, Tomomi Komatsu, Timothy Guenther, Abbey Thiel, Bradley W Bolling, Joshua Hermsen","doi":"10.1186/s41205-026-00321-1","DOIUrl":"10.1186/s41205-026-00321-1","url":null,"abstract":"","PeriodicalId":72036,"journal":{"name":"3D printing in medicine","volume":" ","pages":""},"PeriodicalIF":3.1,"publicationDate":"2026-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC13317428/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147719029","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}