Utilizing a low-cost desktop 3D printer to develop a "one-stop 3D printing lab" for oral and maxillofacial surgery and dentistry fields

3D-printed model for gingival flap surgery simulation: Development and pilot test

INTRODUCTION

To assess the feasibility of a realistic model for learning oral flaps using 3D printing technology.

MATERIALS AND METHODS

A mould was designed to reproduce the mandibular gingival mucosa, and a mandibular model was created using a three-dimensional printer for training undergraduate students to perform gingival flaps. After a short interview about its use, the participants were asked to use the simulator and provide feedback using a 5-point Likert questionnaire.

RESULTS

The 3D-printed oral surgery flap training model was practical and inexpensive. The model was very realistic, educational and useful for hands-on training.

CONCLUSIONS

3D printing technology offers new possibilities for training in dental treatments that are currently difficult to replicate. The use of this simulator for oral flap surgery was well-received and considered promising by the participants.

Trueness of cone-beam computed tomography-derived skull models fabricated by different technology-based three-dimensional printers

BACKGROUND

Three-dimensional (3D) printing is a novel innovation in the field of craniomaxillofacial surgery, however, a lack of evidence exists related to the comparison of the trueness of skull models fabricated using different technology-based printers belonging to different cost segments.

METHODS

A study was performed to investigate the trueness of cone-beam computed tomography-derived skull models fabricated using different technology based on low-, medium-, and high-cost 3D printers. Following the segmentation of a patient's skull, the model was printed by: (i) a low-cost fused filament fabrication printer; (ii) a medium-cost stereolithography printer; and (iii) a high-cost material jetting printer. The fabricated models were later scanned by industrial computed tomography and superimposed onto the original reference virtual model by applying surface-based registration. A part comparison color-coded analysis was conducted for assessing the difference between the reference and scanned models. A one-way analysis of variance (ANOVA) with Bonferroni correction was applied for statistical analysis.

RESULTS

The model printed with the low-cost fused filament fabrication printer showed the highest mean absolute error ([Formula: see text]), whereas both medium-cost stereolithography-based and the high-cost material jetting models had an overall similar dimensional error of [Formula: see text] and [Formula: see text], respectively. Overall, the models printed with medium- and high-cost printers showed a significantly ([Formula: see text]) lower error compared to the low-cost printer.

CONCLUSIONS

Both stereolithography and material jetting based printers, belonging to the medium- and high-cost market segment, were able to replicate the skeletal anatomy with optimal trueness, which might be suitable for patient-specific treatment planning tasks in craniomaxillofacial surgery. In contrast, the low-cost fused filament fabrication printer could serve as a cost-effective alternative for anatomical education, and/or patient communication.

The state of additive manufacturing in dental research - A systematic scoping review of 2012-2022

Background/purpose

Additive manufacturing (AM), also known as 3D printing, has the potential to transform the industry. While there have been advancements in using AM for dental restorations, there is still a need for further research to develop functional biomedical and dental materials. It's crucial to understand the current status of AM technology and research trends to advance dental research in this field. The aim of this study is to reveal the current status of international scientific publications in the field of dental research related to AM technologies.

Materials and methods

In this study, a systematic scoping review was conducted using appropriate keywords within the scope of international scientific publishing databases (PubMed and Web of Science). The review included related clinical and laboratory research, including both human and animal studies, case reports, review articles, and questionnaire studies. A total of 187 research studies were evaluated for quantitative synthesis in this review.

Results

The findings highlighted a rising trend in research numbers over the years (From 2012 to 2022). The most publications were produced in 2020 and 2021, with annual percentage increases of 25.7% and 26.2%, respectively. The majority of AM-related publications in dentistry research originate from Korea. The pioneer dental sub-fields with the ost publications in its category are prosthodontics and implantology, respectively.

Conclusion

The final review result clearly stated an expectation for the future that the research in dentistry would concentrate on AM technologies in order to increase the new product and process development in dental materials, tools, implants and new generation modelling strategy related to AM. The results of this work can be used as indicators of trends related to AM research in dentistry and/or as prospects for future publication expectations in this field.

Fused filament fabrication (FFF): influence of layer height on forces and moments delivered by aligners-an in vitro study

OBJECTIVES

To investigate the effect of layer height of FFF-printed models on aligner force transmission to a second maxillary premolar during buccal torquing, distalization, extrusion, and rotation using differing foil thicknesses.

MATERIALS AND METHODS

Utilizing OnyxCeph3™ Lab (Image Instruments GmbH, Chemnitz, Germany, Release Version 3.2.185), the following movements were programmed for the second premolar: buccal torque (0.1-0.5 mm), distalization (0.1-0.4 mm), extrusion (0.1-0.4 mm), rotation (0.1-0.5 mm), and staging 0.1 mm. Via FFF, 91 maxillary models were printed for each staging at different layer heights (100 µm, 150 µm, 200 µm, 250 µm, 300 µm). Hence, 182 aligners, made of polyethylene terephthalate glycol (PET-G) with two thicknesses (0.5 mm and 0.75 mm), were prepared. The test setup comprised an acrylic maxillary model with the second premolar separated and mounted on a sensor, measuring initial forces and moments exerted by the aligners. A generalized linear model for the gamma distribution was applied, evaluating the significance of the factors layer height, type of movement, aligner thickness, and staging on aligner force transmission.

RESULTS

Foil thickness and staging were found to have a significant influence on forces delivered by aligners, whereas no significance was determined for layer height and type of movement. Nevertheless, at a layer height of 150 µm, the most appropriate force transmission was observed.

CONCLUSIONS

Printing aligner models at particularly low layer heights leads to uneconomically high print time without perceptible better force delivery properties, whereas higher layer heights provoke higher unpredictability of forces due to scattering. A z-resolution of 150 µm appears ideal for in-office aligner production combining advantages of economic print time and optimal force transmission.

Three-Dimensional printed model for preclinical training in oral radiology

INTRODUCTION

3D printing is experiencing significant growth in the teaching and learning process. This study aims to present a 3D printed skull model for preclinical intraoral radiographic practice.

MATERIALS AND METHODS

Two 3D printed mannequins were created. One mannequin used an STL file of a skull that was edited using two 3D modelling software (Meshmixer and Netfabb). The second mannequin was designed directly from a patient's segmented CBCT data and then converted into an STL file. Both mannequins were printed using fused deposition modelling (FDM) technology and polylactic acid (PLA) filament; teeth for the second mannequin were also printed using digital light processing (DLP). The printed skull bones were attached, the mandible was articulated to the articular fossa of the temporal bone, and the teeth were inserted into the alveoli. Intraoral radiographs of both mannequins were taken using a digital sensor (RVG 5100, Carestream).

RESULTS

Both 3D printed mannequins showed satisfactory radiographic appearance, allowing geometric representation of each intraoral radiographic projection, regardless of STL file origin. Anatomical structures, such as the periodontal ligament space, zygomatic process of the maxilla and intermaxillary suture, were represented. The material cost of the first and second printed prototype was $34.00 and $39.00, respectively.

CONCLUSIONS

The use of 3D printed models is presented as an alternative to artificial commercial phantoms for the preclinical training of intraoral radiographic techniques through the combined benefits of superior radiographic projection quality, the possibility of model manipulation and an affordable price.

Comparative Verification of the Accuracy of Implant Models Made of PLA, Resin, and Silicone

Polylactic acid (PLA) has gained considerable attention as an alternative to petroleum-based materials due to environmental concerns. We fabricated implant models with fused filament fabrication (FFF) 3D printers using PLA, and the accuracies of these PLA models were compared with those of plaster models made from silicone impressions and resin models made with digital light processing (DLP). A base model was obtained from an impact-training model. The scan body was mounted on the plaster, resin, and PLA models obtained from the base model, and the obtained information was converted to stereolithography (STL) data by the 3D scanner. The base model was then used as a reference, and its data were superimposed onto the STL data of each model using Geomagic control. The horizontal and vertical accuracies of PLA models, as calculated using the Tukey-Kramer method, were 97.2 ± 48.4 and 115.5 ± 15.1 μm, respectively, which suggests that the PLA model is the least accurate among the three models. In both cases, significant differences were found between PLA and gypsum and between the PLA and resin models. However, considering that the misfit of screw-retained implant frames should be ≤150 µm, PLA can be effectively used for fabricating implant models.

CBCT Images to an STL Model: Exploring the "Critical Factors" to Binarization Thresholds in STL Data Creation

In-house fabrication of three-dimensional (3D) models for medical use has become easier in recent years. Cone beam computed tomography (CBCT) images are increasingly used as source data for fabricating osseous 3D models. The creation of a 3D CAD model begins with the segmentation of hard and soft tissues of the DICOM images and the creation of an STL model; however, it can be difficult to determine the binarization threshold in CBCT images. In this study, how the different CBCT scanning and imaging conditions of two different CBCT scanners affect the determination of the binarization threshold was evaluated. The key to efficient STL creation through voxel intensity distribution analysis was then explored. It was found that determination of the binarization threshold is easy for image datasets with a large number of voxels, sharp peak shapes, and narrow intensity distributions. Although the intensity distribution of voxels varied greatly among the image datasets, it was difficult to find correlations between different X-ray tube currents or image reconstruction filters that explained the differences. The objective observation of voxel intensity distribution may contribute to the determination of the binarization threshold for 3D model creation.

Towards Optimum Mandibular Reconstruction for Dental Occlusal Rehabilitation: From Preoperative Virtual Surgery to Autogenous Particulate Cancellous Bone and Marrow Graft with Custom-Made Titanium Mesh-A Retrospective Study

The purpose of this retrospective study was to evaluate computer-assisted virtual surgery and the outcomes of mandibular reconstruction using an autogenous particulate cancellous bone and marrow (PCBM) graft combined with a custom-made titanium mesh (TiMesh) using a three-dimensional (3D) printing model. Eighteen consecutive patients were included, and preoperative virtual simulation surgery was performed using digital data. Segmental bone defects showed deviation of the mandible due to displacement of the condyle and segments, unnatural length of the mandibular body, or poorer intermaxillary relationship compared to the marginal bone defect caused by previous operations. These mandibular disharmonies could be simulated, and virtual surgery was performed on a computer with adjustment of displaced mandibular segments, length of the mandibular body, and dental arch with digital bone augmentation. TiMesh was manually pre-bent using a 3D printing model, and PCBM from the iliac crest was grafted with TiMesh. The short-term clinical results were good; reconstruction of the alveolar crest was prosthetically desirable; and minor complications were observed. In conclusion, virtual reconstruction is crucial for treating complex deviated mandibles. Accurate condylar and dental arch positions with an optimum mandibular length are important for prosthetically satisfactory mandibular reconstruction.

Fit accuracy of resin crown on a dental model fabricated using fused deposition modeling 3D printing and a polylactic acid filament

Purpose We considered the possibility of reducing industrial waste by fabricating and reusing dental models prepared using a fused deposition modeling (FDM) 3D printer and polylactic acid (PLA) filaments. The purpose of this study was to verify the accuracy of models fabricated using FDM and PLA.Methods The same provisional crown was used to check the marginal fit on PLA models prepared using an intraoral scanner (IOS) and FDM, plaster models made with silicone impression material and plaster, and resin models prepared using an IOS and stereolithography apparatus (SLA) 3D printer. The marginal fit was measured using micro-computed tomography at four points on the tooth: the buccal center (B), palatal center (P), mesial center (M), and distal center (D) points.Results At point B, the marginal gaps were 118 ± 21.7, 62 ± 16.4, and 50 ± 26.5 μm for the PLA, resin, and plaster models, respectively, with a significant difference between the PLA model and the other two. However, the marginal gap at all other measurement points was not significantly different between the models (P > 0.05).Conclusions We compared the accuracy of the models fabricated using the FDM, SLA, and conventional methods. The combination of FDM and PLA filaments showed no significant differences from the other models, except at point B, indicating its usefulness. Therefore, FDM and PLA may become necessary materials for dental treatment in the future.

Introduction of 3D Printing in a German Municipal Hospital-Practice Guide for CMF Surgery

Study Design

This study aimed to introduce 3D printing in a municipal hospital to improve the treatment of craniomaxillofacial patients and optimize costs and operating time. Thus we describe the implementation of low-cost in-house 3D printing to facilitate orbital- and mandible reconstruction in CMF surgery. Moreover, we address legal requirements, safety at work, fire- and data protection. Finally, we want to share our experiences using 3D printing and point out its advantages in providing better patient care.

Methods

We outline the setup of in-house 3D printing and focus on obeying German health care regulations. We based our approach on a fused deposition modeling 3D printer and free software. As proof of concept, we treated 4 cases of severe orbital trauma and 1 case of mandibular reconstruction. We printed a 3D patient-specific model for each case and adapted a titanium mesh implant, respectively, a titanium reconstruction plate before performing the surgery.

Results

Our approach reduced costs, duration of anesthesia, operating time, recovery time, and postoperative swelling and increased the revenue. Functional outcome in orbital reconstruction like eye movement and double vision, was improved compared to the conventional technique. No severe complications like loss-of-vision or surgical revision occurred. Likewise, mandibular reconstruction showed no plate loosening or plate fracture.

Conclusion

The implementation of cost-efficient 3D printing resulted in successful patient treatment with excellent outcomes. Our practice guide offers a 3D printing workflow and could be adapted to fit the needs of other specialties like neurosurgery, orthopedic surgery as well.

Present and future of extraoral maxillofacial prosthodontics: Cancer rehabilitation

Historically, facial prosthetics have successfully rehabilitated individuals with acquired or congenital anatomical deficiencies of the face. This history includes extensive efforts in research and development to explore best practices in materials, methods, and artisanal techniques. Presently, extraoral maxillofacial rehabilitation is managed by a multiprofessional team that has evolved with a broadened scope of knowledge, skills, and responsibility. This includes the mandatory integration of different professional specialists to cover the bio-psycho-social needs of the patient, systemic health and pathology surveillance, and advanced restorative techniques, which may include 3D technologies. In addition, recent digital workflows allow us to optimize this multidisciplinary integration and reduce the active time of both patients and clinicians, as well as improve the cost-efficiency of the care system, promoting its access to both patients and health systems. This paper discusses factors that affect extraoral maxillofacial rehabilitation's present and future opportunities from teamwork consolidation, techniques utilizing technology, and health systems opportunities.

Application of Medical Imaging and 3D Printing Technology in Teaching the Handling of Novel Medicine in Periodontal Surgery

Recently, fibroblast growth factor-2 (FGF-2) agents for periodontal tissue regeneration have been increasingly applied to the treatment of periodontal disease. Our current challenge for resident dentists with little clinical experience is to enhance instruction in the handling of new medicine in addition to teaching conventional procedures in periodontal tissue regeneration. This report describes using case-specific, cost-effective three-dimensional (3D) models for dentists' lectures and periodontal surgical training.

As an educational and training aid, preoperative and postoperative cone-beam computed tomography images were superimposed to enable three-dimensional observation of postoperative bone regeneration. A three-dimensional anatomical model was fabricated based on these images. Dental laboratory materials were used to reproduce the periosteum and gum. The fabrication time per 3D model was about 2 hours and the cost per model was about $0.5. These models were used for lectures to resident dentists and periodontal surgery training, and their feedback was obtained. The resident's response to surgical training using these 3D models was generally positive.

The use of FGF-2 represents a new direction in the treatment of periodontal disease. This being new, however, means that inexperienced periodontists require training in its application and how this will affect prognosis, as this will differ from that with more conventional techniques aimed at tissue regeneration. The low-cost 3D model presented in this report can be a valuable tool to help accomplish this in teaching inexperienced dentists, such as resident dentists.

Fused Deposition Modeling 3D Printing in Oral and Maxillofacial Surgery: Problems and Solutions

Three-dimensional (3D) printing technology in medicine is one of the new and innovative technology for fabricating 3D models of complex anatomical structures that can be observed both visually and haptically. Patient-specific 3D models fabricated through this process are currently being used for various purposes, including surgical simulation, training, and medical education. Most of the personal use/low-end desktop 3D printers that are becoming widespread are fused deposition modeling (FDM) 3D printers. Compared to professional/high-end 3D printers, the price of the personal use/low-end desktop FDM 3D printer itself, filament, and running costs are lower; it can lower the economic bottleneck for introducing 3D printing technology into clinical practice, such as surgical simulation. With a desktop FDM 3D printer and a general-purpose PC, anyone can now rapidly fabricate 3D models on their own without having to rely on 3D printing labs and specialized technicians. However, it is also true that FDM 3D printers, due to their mechanical characteristics, encounter many difficulties and problems that emerge during the 3D printing process. Knowledge, know-how, and tips about FDM 3D printers have been introduced in various media, and it has become easy to know about them worldwide via the Internet. However, there has been no comprehensive technical review to date to produce osseous 3D models for use in oral and maxillofacial surgery. In this report, to create 3D models according to the characteristics of maxillofacial and oral surgery, we enable surgeons themselves to create 3D models smoothly by presenting ideas for CT scanning, points to note when exporting Digital Imaging and Communications in Medicine (DICOM) image data, how to create optimal stereolithography (STL) models, and problems and solutions for 3D printing.

Color translation from monoscopic photogrammetry +ID Methodology into a Polyjet final 3D printed facial prosthesis

Background: The artistic techniques necessary to fabricate facial prostheses mainly depend on individual skill and are not a resource easily reproduced. Digital technology has contributed to improved outcomes, often combining analog and new digital techniques in the same workflow. Methods: This article aims to present an innovative workflow to produce a final colored 3D printed and facial prosthesis by UV-map color translation into colored resin 3D printing. A modified +ID Methodology was used to obtain 3D models with the calibrated 3D printable patient's skin color. No hands-on physical molding, manual sculpture, or intrinsic silicone coloration was used. Results: The outcome resulted in acceptable aesthetics, adaptation, and an approximate color match after extrinsic coloration. The patient reported good comfort and acceptance. Conclusions: A direct resin 3D printed prosthesis may be a viable alternative, especially for rapid delivery as an immediate prosthesis or an option when there is no experienced anaplastogist to manufacture a conventional prosthesis.

A focused simulation-based optimization of print time and material usage with respect to orientation, layer height and support settings for multi-pathological anatomical models in inverted vat photopolymerization 3D printing

Background

3D printing of anatomical models requires multi-factorial decision making for optimal model manufacturing. Due to the complex nature of the printing process, there are frequently multiple potentialities based on the desired end goal. The task of identifying the most optimal combination of print control variables is inherently subjective and rests on sound operator intuition. This study investigates the effect of orientation, layer and support settings on print time and material usage. This study also presents a quantitative optimization framework to jointly optimize print time and material usage as a function of those settings for multi-pathological anatomical models.

Methods

Seven anatomical models representing different anatomical regions (cardiovascular, abdominal, neurological and maxillofacial) were selected for this study. A reference cube was also included in the simulations. Using PreForm print preparation software the print time and material usage was simulated for each model across 4 orientations, 2 layer heights, 2 support densities and 2 support tip sizes. A 90–10 weighted optimization was performed to identify the 5 most optimal treatment combinations that resulted in the lowest print time (90% weight) and material usage (10% weight) for each model.

Results

The 0.1 mm layer height was uniformly the most optimal setting across all models. Layer height had the largest effect on print time. Orientation had a complex effect on both print time and material usage in certain models. The support density and the support tip size settings were found to have a relatively minor effect on both print time and material usage. Hollow models had a larger support volume fraction compared to solid models.

Conclusions

The quantitative optimization framework identified the 5 most optimal treatment combinations for each model using a 90–10 weighting for print time and material usage. The presented optimization framework could be adapted based on the individual circumstance of each 3D printing lab and/or to potentially incorporate additional response variables of interest.

From CT to 3D Printed Models, Serious Gaming, and Virtual Reality: Framework for Educational 3D Visualization of Complex Anatomical Spaces From Within-the Pterygopalatine Fossa

We describe the framework for capturing the internal view of complex anatomical spaces via multiple media and haptic platforms, exemplified by realistic and conceptual representations of the pterygopalatine fossa (PPF). A realistic three-dimensional (3D) mesh of the PPF was developed by segmenting the osseous anatomy on computed tomography (CT) using Materialize InPrint. Subsequently in Autodesk 3D Studio Max, the realistic mesh was enhanced with graphically designed neurovascular anatomy and additionally a conceptual representation of the PPF with its connections and contents was created. An interactive web-compatible Adobe Flash tutorial using ActionScript was developed, allowing users to advance through a series of educational slides that contained interactive rotatable interior camera views and scrollable CT cross-sectional content, incorporating both the realistic and conceptual models. Both models were also 3D printed using polyamide material. In the realistic model, the neurovasculature was colored with water-based acrylic paint. A 3-piece modular design with embedded magnets allows for internal visualization and seamless assembly. A serious gaming environment of the conceptual PPF was also developed using Truevision3D application programming interface, where users can freely move around rooms and hallways that represent various spaces. Lastly, the realistic model was incorporated into a headset-based virtual reality environment, Surgical Theater, allowing visualization and fly-through inside and outside the model. Multiple 3D techniques for visualization of complex 3D anatomical spaces from within were described, with the necessary software and skills detailed. A rough estimate of the time and cost needed to develop these tools as well as multiple supplementary source and end result files are also made available. Educators could utilize multiple advanced delivery methods to incorporate custom digital 3D models of complex anatomical spaces understood from inside.

3D printing in oral and maxillofacial surgery: a nationwide survey among university and non-university hospitals and private practices in Germany

OBJECTIVES

Oral and maxillofacial surgery (OMFS) has undergone pioneering progress through the development of three-dimensional (3D) printing technologies. The aim of this study was to evaluate the use of 3D printing at OMFS university and non-university hospitals and private practices in Germany.

MATERIALS AND METHODS

For explorative assessment, a dynamic online questionnaire containing 10-22 questions about the current use of 3D printing and the reasons behind it was sent to OMFS university and non-university hospitals and private practices in Germany by the study group from the German Association of Oral and Maxillofacial Surgery (DGMKG).

RESULTS

In total, 156 participants responded from university (23 [14.7%]) and non-university hospitals (19 [12.2%]) and private practices without (85 [50.5%]) and with 29 (18.6%) inpatient treatment facility. Highest applications of 3D printing were in implantology (57%), microvascular bone reconstructions (25.6%), and orthognathics (21.1%). Among the participants, 37.8% reportedly were not using 3D printing. Among the hospitals and private practices, 21.1% had their own 3D printer, and 2.5% shared it with other departments. The major reason for not having a 3D printer was poor cost efficiency (37.6%). Possessing a 3D printer was motivated by independence from external providers (91.3%) and rapid template production (82.6%). The preferred printing methods were stereolithography (69.4 %) and filament printing (44.4%).

CONCLUSIONS

OMFS 3D printing is established in Germany with a wide range of applications.

CLINICAL RELEVANCE

The prevalence of 3D printing in hospitals and private practices is moderate. This may be enhanced by future innovations including improved cost efficiency.

Accuracy of desktop versus professional 3D printers for maxillofacial model production. A systematic review and meta-analysis

OBJECTIVES

The present review systematically analyzed the accuracy of three-dimensional (3D) maxillofacial skeletal models generated from desktop and professional 3D printers.

DATA/SOURCES

Electronic literature search was conducted in the following databases: PubMed, Embase, Web of Science and Cochrane Library up to September 2020. Two reviewers independently performed the study selection, data extraction and quality assessment of the included studies. Risk of bias was assessed using the Joanna Briggs Critical Appraisal Checklist for Diagnostic Test Accuracy.

STUDY SELECTION/RESULTS

The search strategy retrieved 5680 articles. Following removal of duplicates, title and abstract screening and full-text reading, 20 publications were eligible to be included in the review which focused towards the accuracy of skeletal models generated from either desktop or professional printer. Both types of printers were defined based on their cost, size and layer thickness, where desktop printers cost between $1500-$7000, have a build size of 10×10×10 inches or less and a minimum layer thickness of 100 µm. Whereas, the professional printers cost was between $20,000- $200,000 with a build size of 12×12×12 inches or more and a layer thickness of as less as 3 µm. The risk of bias was found to be low to moderate. Meta-analysis results indicated no significant absolute mean difference (AMD) (p = 0.9487) between desktop (0.12 mm, 95% CI: 0.00-0.27 mm) and professional printers (0.10 mm, 95% CI: 0.04-0.16 mm). Amongst the printing technology, material jetting (0.09 mm, 95% CI: 0.00-0.17 mm) and selective laser sintering (0.09 mm, 95% CI: 0.00-0.26 mm) offered the lowest AMD and the highest difference was observed with the fused deposition modeling (0.22 mm, 95% CI: 0.00-0.53 mm).

CONCLUSIONS

The maxillofacial skeletal models generated from desktop printers offered comparable accuracy to that acquired with professional printers.

CLINICAL SIGNIFICANCE

The desktop 3D printers may be a viable option to print maxillofacial skeletal models for surgical planning, simulation, guide manufacturing and education purposes.

Print and Try Technique: 3D-Printing of Teeth with Complex Anatomy a Novel Endodontic Approach

The purpose of this report is to evaluate the applicability of a novel Print and Try technique in the presence of aberrant endodontic anatomies and to achieve a predictable treatment with improved outcome. According to guidelines, cone beam computed tomography (CBCT) is recommended in the presence of complex anatomies. The volumes were utilized to produce a stereo lithographic (STL) file, from which a 3D-plastic tooth model including a hollow root canal system was obtained. The 3D-patient-specific model facilitates the treatment planning and the trial of therapeutic approaches. Using a transparent material, all the treatment steps could be directly visualized. Subsequently, endodontic therapy could be performed in vivo with reduced operating time and with a better overview. Clinicians benefit from the Print and Try technique when facing a complicated root canal system with reduced stress and higher chances of success. In aberrant endodontic anatomies, the use of a transparent 3D plastic model, derived from the CBCT dicom, provides an exact preview of clinical challenges that will be met intra-operatively. A patient centered tailored approach to shaping, cleaning, and filling strategies can be applied.

Effects of printing layer thickness on mechanical properties of 3D-printed custom trays

STATEMENT OF PROBLEM

The layer thickness serves as a straightforward and controllable parameter to alter the mechanical properties of 3D-printed custom trays. However, how the printing layer thickness affects the mechanical properties of the trays is not fully understood.

PURPOSE

The purpose of this in vitro study was to investigate the effects and their underlying mechanisms and to optimize the mechanical properties through modulation of the printing layer thickness.

MATERIAL AND METHODS

Polylactic acid (PLA) specimens were 3D-printed with 5 layer thicknesses from 0.1 mm to 0.5 mm. The bond, flexural, and tensile strengths were measured by using a universal test machine. Postfracture interfaces were examined by means of scanning electron microscopy. Additionally, the printing dimensional accuracy was estimated by measuring the size deviations between the printed and virtual specimens, and the printing times were recorded.

RESULTS

With increasing PLA printing layer thickness, the tensile bond strength first increased and then decreased, peaking at a thickness of 0.4 mm. While the flexural and tensile strengths decreased, the printing dimensional accuracy remained constant from 0.1 mm to 0.4 mm and then decreased at 0.5 mm. The printing time sharply decreased as printing layer thickness increased.

CONCLUSIONS

Moderate layer thickness provided the best properties for 3D-printed custom trays.

Clinical Applications of Patient-Specific 3D Printed Models in Cardiovascular Disease: Current Status and Future Directions

Three-dimensional (3D) printing has been increasingly used in medicine with applications in many different fields ranging from orthopaedics and tumours to cardiovascular disease. Realistic 3D models can be printed with different materials to replicate anatomical structures and pathologies with high accuracy. 3D printed models generated from medical imaging data acquired with computed tomography, magnetic resonance imaging or ultrasound augment the understanding of complex anatomy and pathology, assist preoperative planning and simulate surgical or interventional procedures to achieve precision medicine for improvement of treatment outcomes, train young or junior doctors to gain their confidence in patient management and provide medical education to medical students or healthcare professionals as an effective training tool. This article provides an overview of patient-specific 3D printed models with a focus on the applications in cardiovascular disease including: 3D printed models in congenital heart disease, coronary artery disease, pulmonary embolism, aortic aneurysm and aortic dissection, and aortic valvular disease. Clinical value of the patient-specific 3D printed models in these areas is presented based on the current literature, while limitations and future research in 3D printing including bioprinting of cardiovascular disease are highlighted.

Dimensional Accuracy of Dental Casting Patterns Fabricated Using Consumer 3D Printers

Consumer 3D printers have improved considerably due to the evolution of additive manufacturing. This study aimed to examine the accuracy of consumer printers in dental restoration. Cylindrical patterns mimicking a full crown were created and enlarged from 100% to 105% of the original size. Two types of consumer 3D printers, including a fused deposition modeling (FDM) device and a stereolithography (SLA) device, and two types of dental 3D printers, including a multi-jet device and an SLA device, were used to fabricate the patterns. Then, the outer and inner diameters and depths, and surface roughness of the patterns were measured. The changing rates of the outer diameter of models created using dental printers were significantly smaller than those of the models created using consumer printers (p < 0.05). Significantly greater surface roughness was obtained in the tooth axis of the model fabricated using the consumer FDM device (p < 0.05). However, no significant differences were observed on the surface roughness of both axes between the consumer SLA device and the dental devices (p > 0.05). However, FDM showed larger surface roughness than dental devices in both axes (p < 0.05). Thus, the SLA consumer printer can be applied to fabricate resin patterns with enlargement editing of 1–3% along the horizontal axis.

The impact of 3D-printed LAY-FOMM 40 and LAY-FOMM 60 on L929 cells and human oral fibroblasts

Objectives

LAY-FOMM is a promising material for FDA-approved Fused Deposition Modeling (FDM) applications in drug delivery. Here we investigated the impact on oral cells.

Materials and methods

We evaluated the impact of 3D-printed LAY-FOMM 40, LAY-FOMM 60, and biocompatible polylactic acid (PLA) on the activity of murine L929 cells, gingival fibroblasts (GF), and periodontal ligament fibroblasts (PDLF) using indirect (samples on cells), direct monolayer culture models (cells on samples), and direct spheroid cultures with resazurin-based toxicity assay, confirmed by MTT and Live-dead staining. The surface topography was evaluated with scanning electron microscopy.

Results

The materials LAY-FOMM 40 and LAY-FOMM 60 led to a reduction in resazurin conversion in L929 cells, GF, and PDLF, higher than the impact of PLA in indirect and direct culture models. Fewer vital cells were found in the presence of LAY-FOMM 40 and 60 than PLA, in the staining in both models. In the direct model, LAY-FOMM 40 and PLA showed less impact on viability in the resazurin-based toxicity assay than in the indirect model. Spheroid microtissues showed a reduction of cell activity of GF and PDLF with LAY-FOMM 40 and 60.

Conclusion

Overall, we found that LAY-FOMM 40 and LAY-FOMM 60 can reduce the activity of L292 and oral cells. Based on the results from the PLA samples, the direct model seems more reliable than the indirect model.

Clinical relevance

A material modification is desired in terms of biocompatibility as it can mask the effect of drugs and interfere with the function of the 3D-printed device.

Utilization of desktop 3D printer-fabricated "Cost-Effective" 3D models in orthognathic surgery

Background

In daily practice, three-dimensional patient-specific jawbone models (3D models) are a useful tool in surgical planning and simulation, resident training, patient education, and communication between the physicians in charge. The progressive improvements of the hardware and software have made it easy to obtain 3D models. Recently, in the field of oral and maxillofacial surgery, there are many reports on the benefits of 3D models. We introduced a desktop 3D printer in our department, and after a prolonged struggle, we successfully constructed an environment for the "in-house" fabrication of the previously outsourced 3D models that were initially outsourced. Through various efforts, it is now possible to supply inexpensive 3D models stably, and thus ensure safety and precision in surgeries. We report the cases in which inexpensive 3D models were used for orthodontic surgical simulation and discuss the surgical outcomes.

Review

We explained the specific CT scanning considerations for 3D printing, 3D printing failures, and how to deal with them. We also used 3D models fabricated in our system to determine the contribution to the surgery. Based on the surgical outcomes of the two operators, we compared the operating time and the amount of bleeding for 25 patients who underwent surgery using a 3D model in preoperative simulations and 20 patients without using a 3D model. There was a statistically significant difference in the operating time between the two groups.

Conclusions

In this article, we present, with surgical examples, our in-house practice of 3D simulation at low costs, the reality of 3D model fabrication, problems to be resolved, and some future prospects.

DICOM segmentation and STL creation for 3D printing: a process and software package comparison for osseous anatomy

BACKGROUND

Extracting and three-dimensional (3D) printing an organ in a region of interest in DICOM images typically calls for segmentation as a first step in support of 3D printing. The DICOM images are not exported to STL data immediately, but segmentation masks are exported to STL models. After primary and secondary processing, including noise removal and hole correction, the STL data can be 3D printed. The quality of the 3D model is directly related to the quality of the STL data. This study focuses and reports on the DICOM to STL segmentation performance for nine software packages.

METHODS

Multidetector row CT scanning was performed on a dry human mandible with two 10-mm-diameter bearing balls as a phantom. The DICOM image file was then segmented and exported to an STL file using nine different commercial/open-source software packages. Once the STL models were created, the data (file) properties and the size and volume of each file were measured, and differences across the software packages were noted. Additionally, to evaluate differences between the shapes of the STL models by software package, each pair of STL models was superimposed, with the observed differences between their shapes characterized as the shape error.

RESULTS

The data (file) size of the STL file and the number of triangles that constitute each STL model were different across all software packages, but no statistically significant differences were found across software packages. The created ball STL model expanded in the X-, Y-, and Z-axis directions, with the length in the Z-axis direction (body axis direction) being slightly longer than that in the other directions. The mean shape error between software packages of the mandibular STL model was 0.11 mm, but there was no statistically significant difference between them.

CONCLUSIONS

Our results revealed that there are some differences between the software packages that perform the segmentation and STL creation of the DICOM image data. In particular, the features of each software package appeared in the fine and thin areas of the osseous structures. When using these software packages, it is necessary to understand the characteristics of each.

Accuracy of cardiac magnetic resonance generated 3D models of the aortic annulus compared to cardiovascular computed tomography generated 3D models

To evaluate the accuracy of 3D models of the aortic-root generated from non-contrast cardiac magnetic resonance (CMR). Data were retrospectively collected from 30 consecutive patients who underwent surgical aortic valve replacement and had available records of both intra-operative assessment and pre-surgery annulus assessment by cardiovascular computed tomography (CCT) and CMR. The 3D models were independently segmented, modelled and printed by two blinded "manufacturers". The measurements on the models were carried out by two cardiac surgeons with Hegar dilator. Data were analyzed with non-parametric tests. There was no significant intra- or inter-observer variability (p ≥ 0.13). The agreement between the diameter of the 3D model derived from CMR images and either the anatomical reference of the intraoperative measurement (p = 0.10, r = 0.97) or the radiological reference of the 3D model generated from CCT (p = 0.71, r = 0.92) was very good. The process of segmentation plus the post-processing was about 17 ± 2 min for a model created by CMR, significantly higher than a model created from CCT (7 ± 2 min; p < 0.001). The printing time for a single model did not differ between the two modalities (p = 0.61) and was less than 60 min. The cost for a single model was approximately 0.5 €. 3D models generated from non-contrast CMR performed well when compared to the anatomical reference standard and are comparable to the pair CCT derived models.

Cost-Effective Method for 3-Dimensional Printing Dynamic Multiobject and Patient-Specific Brain Tumor Models: Technical Note

BACKGROUND

Three-dimensional (3D) printing is a powerful tool for replicating patient-specific anatomic features for education and surgical planning. The advent of "desktop" 3D printing has created a cost-effective and widely available means for institutions with limited resources to implement a 3D-printing workflow into their clinical applications. The ability to physically manipulate the desired components of a "dynamic" 3D-printed model provides an additional dimension of anatomic understanding. There is currently a gap in the literature describing a cost-effective and time-efficient means of creating dynamic brain tumor 3D-printed models.

METHODS

Using free, open-access software (3D Slicer) for patient imaging to Standard Tessellation Language file conversion, as well as open access Standard Tessellation Language editing software (Meshmixer), both intraaxial and extraaxial brain tumor models of patient-specific pathology are created.

RESULTS

A step-by-step methodology and demonstration of the software manipulation techniques required for creating cost-effective, multidimensional brain tumor models for patient education and surgical planning are exhibited using a detailed written guide, images, and a video display.

CONCLUSIONS

In this technical note, we describe in detail the specific functions of free, open-access software and desktop 3D printing techniques to create dynamic and patient-specific brain tumor models for education and surgical planning.

Biomechanical Analysis of Various Reconstructive Methods for the Mandibular Body and Ramus Defect Using a Free Vascularized Fibula Flap

Several different methods exist for reconstructing the mandibular body and ramus defect with the use of a free vascularized fibula flap, but none have adequately addressed the long-term mechanical stability and osseointegration. The aim of this study is to compare the biomechanics of different surgical methods and to investigate the best approach for reconstructing the mandibular body and ramus defect. Five finite element models based on different reconstructive methods were simulated. Stress, strain, and displacement of connective bone sections were calculated for five models and compared. The models were printed using a 3D printer, and stiffness was measured using an electromechanical universal testing machine. The postoperative follow-up cone beam computed tomography (CBCT) was taken at different time points to analyze bone mineral density of connective bone sections. The results showed that the “double up” (DU) model was the most efficient for reconstructing a mandibular body and ramus defect by comparing the mechanical distribution of three sections under vertical and inclined loading conditions of 100 N. The stiffness detection showed that stiffness in the DU and “double down” (DD) models was higher compared with the “single up” (SU), “single down” (SD), and “distraction osteogenesis” (DO) models. We used the DU model for the surgery, and postoperative follow-up CBCT showed that bone mineral density of each fibular connective section increased gradually with time, plateauing at 12 weeks. We conclude that a free vascularized fibula flap of the DU type was the best approach for the reconstruction of the mandibular body and ramus defect. Preoperative finite element analysis and stiffness testing were shown to be very useful for maxillofacial reconstruction.

What would you like to print? Students' opinions on the use of 3D printing technology in medicine

Background

Recent advances in 3D printing technology, and biomaterials are revolutionizing medicine. The beneficiaries of this technology are primarily patients, but also students of medical faculties. Taking into account that not all students have full, direct access to the latest advances in additive technologies, we surveyed their opinion on 3D printing and education in this area. The research aimed to determine what knowledge about the use of 3D printing technology in medicine, do students of medical faculties have.

Methods

The research was carried out in the form of a questionnaire among 430 students of the Medical University of Silesia in Katowice (Poland) representing various fields of medicine and health sciences. The questions included in the survey analyzed the knowledge of the respondents for 3D printing technology and the opportunities it creates in medicine.

Results

The results indicate that students do have knowledge about 3D printing obtained mainly from the internet. They would be happy to deepen their knowledge at specialized courses in this field. Students appreciated the value of 3D printing in order to obtain accurate anatomical models, helpful in learning. However, they do not consider the possibility of complete abandonment of human cadavers in the anatomy classes. Their knowledge includes basic information about current applications of 3D printing in medicine, but not in all areas. However, they have no ethical doubts regarding the use of 3D printing in any form. The vast majority of students deemed it necessary to incorporate information regarding 3D printing technology into the curriculum of different medical majors.

Conclusion

This research is the first of its kind, which allows for probing students' knowledge about the additive technologies in medicine. Medical education should be extended to include issues related to the use of 3D printing for medical applications.

Digital dentistry: The new state of the art - Is it disruptive or destructive?

OBJECTIVE

Summarizing the new state of the art of digital dentistry, opens exploration of the type and extent of innovations and technological advances that have impacted - and improved - dentistry. The objective is to describe advances and innovations, the breadth of their impact, disruptions and advantages they produce, and opportunities created for material scientists.

METHODS

On-line data bases, web searches, and discussions with industry experts, clinicians, and dental researchers informed the content. Emphasis for inclusion was on most recent publications along with innovations presented at trade shows, in press releases, and discovered through discussions leading to web searches for new products.

RESULTS

Digital dentistry has caused disruption on many fronts, bringing new techniques, systems, and interactions that have improved dentistry. Innovation has spurred opportunities for material scientists' future research.

SIGNIFICANCE

With disruptions intrinsic in digital dentistry's new state of the art, patient experience has improved. More restoration options are available delivering longer lifetimes, and better esthetics. Fresh approaches are bringing greater efficiency and accuracy, capitalizing on the interest, capabilities, and skills of those involved. New ways for effective and efficient inter-professional and clinician-patient interactions have evolved. Data can be more efficiently mined for forensic and epidemiological uses. Students have fresh ways of learning. New, often unexpected, partnerships have formed bringing further disruption - and novel advantages. Yes, digital dentistry has been disruptive, but the abundance of positive outcomes argues strongly that it has not been destructive.

Evaluation of mechanical properties of new elastomer material applicable for dental 3D printer

PURPOSE

Digital technology has advanced and changed clinical dentistry. The utility of various thermoplastic materials for 3D dental printing has not been thoroughly explored. The aim of this study was to evaluate mechanical properties of a new thermoplastic elastomer material applicable for a dental 3D printer.

MATERIAL & METHOD

Three thermoplastic elastomers: ABS, PLA and an acrylic block copolymer (KUR) and a dental self-curing resin (PMMA) were used in this study. Physical properties were evaluated by measuring water sorption (WS), dimensional accuracy (DA), ultimate tensile strength (UTS) and shear bond strength (SBS) to PMMA. For WS and DA, specimens were measured by weight and length, respectively after desiccation and immersion in 37 °C distilled water for 1 day, 1 week and 1 month. For UTS, the specimens were prepared according to ISO 527-2-5A and loaded to test the UTS at a crosshead speed of 5 mm/min after storage in 37 °C distilled water for 24 h and 1 month. For SBS, MMA self-curing resin was filled in a Teflon ring which was mounted onto polished specimens to make the adhesive area. The prepared specimens were tested for SBS after storage in 37 °C distilled water for 24 h and 37 °C distilled water for 24 h followed by 10000 times thermal cycling. The data were analyzed by repeated measures ANOVA, two-way ANOVA and t-test with Bonferroni correction at 95% confidence level.

RESULT

The WS value of PMMA was significantly higher than those of the other materials after 1 day (p < 0.05), while the WS values of KUR were significantly higher than those of the other materials after 1 week and 1 month (p < 0.05). The DA values were influenced by water storage periods except for KUR. There were no significant differences among ABS, PLA and PMMA in SBS before thermal cycling (p > 0.05). The SBS of KUR was the lowest among the materials before thermal cycling (p < 0.05). However, there was no significant difference between PMMA and KUR after thermal cycling (p > 0.05).

CONCLUSION

The acrylic block copolymer demonstrated acceptable physical properties, suggesting the potential to be a material to make provisional restorations for a dental 3D printer.

Photogrammetry as an alternative for acquiring digital dental models: A proof of concept

Photogrammetry is a mathematical technique that generates three-dimensional coordinates of specific points identified from multiple images of the same object obtained at different angles. This technique may be a low-cost alternative for traditional scanning. The objective of this proof of concept was to evaluate the accuracy and precision in obtaining digital models (DM) from a plaster model (PM) using photogrammetry. Five DM were generated from 50 photographs taken surrounding the PM. The photographs were taken by a single operator on five consecutive days using natural light. The images obtained were processed on 3DF Zephyr Free software. The height and width of all teeth were recorded on both PM and DM, as well as the distance between the canine cusps (C-C) and between the mesiobuccal cusps of the first molars (1 M-1 M). For the PM the measurements were taken with a digital caliper, whereas the DM was measured using the software Blender. The DM and PM measurements presented a limit of agreement between -0.433 and 0.611 mm. The accuracy of DM measurements showed a SD of ±0.171 mm and a repeatability coefficient of 0.474. In the superimposition of all DM, it was possible to notice a greater discrepancy in the posterior region of the arch and palate, but this difference decreased when the region was segmented. It can be concluded that photogrammetry appears to be a viable technique for the digitization of dental models. Further studies need to be performed to evaluate its clinical application.

Prognostic factors for maxillary sinus mucosal thickening following Le Fort I osteotomy: a retrospective analysis

Background

Le Fort I osteotomy is one of the surgical procedures now routinely and safely performed. It is possible to move the maxilla in three dimensions, but it is necessary to separate the bones around the maxillary sinus. Therefore, with surgery, maxillary sinus mucosal thickening occurs. By knowing the changes in the sinus mucosa after surgery and the factors affecting it, it is possible to better predict the outcomes of surgery and contribute to safer surgery. In this study, thickening of maxillary sinus mucosa before and after surgery in Le Fort I osteotomy was evaluated using multidetector-row computed tomography (MDCT) images, and the changes in mucosal thickening and the related factors were examined.

Methods

Using MDCT images, the maxillary sinus mucosa of 125 patients who had undergone Le Fort I osteotomy was retrospectively evaluated before surgery, 1 month after surgery, and 1 year after surgery. On the MDCT images, the maxillary sinus was judged as mucosal thickening and classified into three grades according to the proportion occupying the maxillary sinus. In the evaluation of factors related to mucosal thickening, the following eight factors were examined: sex, age, diagnosis, operating time, amount of postoperative bleeding, with/without bone graft, with/without multisegmental osteotomy, and with/without macrolide therapy after surgery.

Results

The mean age at the time of surgery was 25.6 ± 8 years. Of all 125 patients, 66 had bilateral thickening, 19 had unilateral thickening, and 40 had no thickening. Factors that were significantly related to mucosal thickening were the operative time for the maxilla, bone grafts, and macrolide therapy after surgery.

Conclusions

Operative time for the maxilla, bone grafts, and macrolide therapy after surgery were found to be related to mucosal thickening. In addition, MDCT scanning 1 month after surgery was considered to be appropriate for evaluation of maxillary sinus mucosal thickening.

Mechanical Analysis of Ceramic/Polymer Composite with Mesh-Type Lightweight Design Using Binder-Jet 3D Printing

3D printing technology has recently been highlighted as an innovative manufacturing process. Among various 3D printing methods, binder jetting (BJ) 3D printing is particularly known as technology used to produce the complex sand mold quickly for a casting process. However, high manufacturing costs, due to its expensive materials, need to be lowered for more industrial applications of 3D printing. In this study, we investigated mechanical properties of sand molds with a lightweight structure for low material consumption and short process time. Our stress analysis using a computational approach, revealed a structural weak point in the mesh-type lightweight design applied to the 3D-printed ceramic/polymer composite.