On producing customised soft-tissue prostheses using digital tools and silicone casting techniques

Summary form only given. Physical and emotional problems can be prominent whenever a significant loss of a critical part of the face or body (e.g., nose, ears, eyes and fingers) is involved. Resulting from neoplasms, congenital malformations, burns, trauma, among others, the solution for these external defects, whenever a surgical reconstruction is impractical or counter-indicated, are conventionally addressed by an anaplastologist, who produces customised prostheses throughout a manual and time-consuming procedure via lifecasting techniques. Currently, advances on computational technologies have given rise to a digital-based method. This approach is used herein for the design and fabrication of personalised silicone prostheses. In this work, an efficient and cost-effective manufacturing methodology, able to produce accurate prostheses with a high-resolution level (e.g. wrinkles, fingerprints) is proposed. This framework entails six tasks: (i) data acquisition, (ii) 3D reconstruction, (iii) prosthesis design, (iv) mould fabrication, (v) prosthesis manufacturing and, (vi) final fittings [1]. First, regarding data acquisition, two technologies are taken into consideration, namely medical imaging or 3D scanning photometry. After the 3D reconstruction, for the prosthesis design, 3D measuring and design operations are carried out in an STL editor. This provides modelling tools targeting a good fitting between the surface models of the failing part and symmetric or donor organ. Also, a main issue to be addressed in this step is the fixation system, which is fundamental to ensure a good prosthesis retention. Following, a SLA-prototype is fabricated and the mould is produced via silicone casting. The prosthesis manufacturing is performed using pigmented silicon considering patient's skin tone. Nails, hair and/or extrinsic coloration may be include in order to accomplish a more realistic appearance of the prosthesis. The proposed approach showed encouraging outcomes, providing a comfortable solution, reducing the processing time, and disclosing excellent aesthetic results [1].