Quality assurance in 3D-printing: A dimensional accuracy study of patient-specific 3D-printed vascular anatomical models

Insights into geometric deviations of medical 3d-printing: a phantom study utilizing error propagation analysis

BACKGROUND

The use of 3D-printing in medicine requires a context-specific quality assurance program to ensure patient safety. The process of medical 3D-printing involves several steps, each of which might be prone to its own set of errors. The segmentation error (SegE), the digital editing error (DEE) and the printing error (PrE) are the most important partial errors. Approaches to evaluate these have not yet been implemented in a joint concept. Consequently, information on the stability of the overall process is often lacking and possible process optimizations are difficult to implement. In this study, SegE, DEE, and PrE are evaluated individually, and error propagation is used to examine the cumulative effect of the partial errors.

METHODS

The partial errors were analyzed employing surface deviation analyses. The effects of slice thickness, kernel, threshold, software and printers were investigated. The total error was calculated as the sum of SegE, DEE and PrE.

RESULTS

The higher the threshold value was chosen, the smaller were the segmentation results. The deviation values varied more when the CT slices were thicker and when the threshold was more distant from a value of around -400 HU. Bone kernel-based segmentations were prone to artifact formation. The relative reduction in STL file size [as a proy for model complexity] was greater for higher levels of smoothing and thinner slice thickness of the DICOM datasets. The slice thickness had a minor effect on the surface deviation caused by smoothing, but it was affected by the level of smoothing. The PrE was mainly influenced by the adhesion of the printed part to the build plate. Based on the experiments, the total error was calculated for an optimal and a worst-case parameter configuration. Deviations of 0.0093 mm ± 0.2265 mm and 0.3494 mm ± 0.8001 mm were calculated for the total error.

CONCLUSIONS

Various parameters affecting geometric deviations in medical 3D-printing were analyzed. Especially, soft reconstruction kernels seem to be advantageous for segmentation. The concept of error propagation can contribute to a better understanding of the process specific errors and enable future analytical approaches to calculate the total error based on process parameters.

Accuracy of intertrochanteric osteotomy for patients with slipped capital femoral epiphysis operated with 3D printed patient-specific guides

BACKGROUND

Slipped Capital Femoral Epiphysis (SCFE), is one of the most common hip disorders in adolescents, and is treated surgically by performing an Imhäuser osteotomy. The use of 3D printed guides has shown promise in improving the accuracy of the osteotomy. However, misplacement of the guide may limit the improvement. Therefore, the aim of this study was to investigate, postoperatively, the degree of malalignment of 3D printed guides compared to the 3D planning.

METHODS

Patients who underwent surgery between April 2018 and October 2022 and underwent postoperative CT were included in this study. The preoperative CT was used for 3D planning of surgical treatment using 3D printed patient-specific guides and plates. The positioning error of the femoral head and of the patient-specific guide and plate was quantified by analysing the postoperative CT scans using custom software.

RESULTS

Five SCFE patients were included in the study. Femoral head malalignment improved from 16 to 40 mm preoperatively to 11-17 mm postoperatively. Rotational malalignment improved from 29-63⁰ preoperatively to 15-31⁰ postoperatively. Residual error was mostly attributed to plate malposition, with residual translation in the range of 3-13 mm and rotation of 8-28⁰.

CONCLUSION

Although the postoperative position improved after surgery with 3D printed surgical guides and plates, there was a residual deviation from the planned position persisted. Further research is recommended to improve the design, accuracy of guide placement and surgery in this anatomically challenging region.

[Effectiveness of sacroiliac screw implantation assisted by three-dimensional printed faceted honeycomb guide plate in treatment of posterior pelvic ring fracture]

Objective

To investigate the effectiveness of sacroiliac screw implantation assisted by three-dimensional (3D) printed faceted honeycomb guide plate in the treatment of posterior pelvic ring fracture.

Methods

The clinical data of 40 patients with posterior pelvic ring fractures treated with sacroiliac screw implantation between December 2019 and December 2022 were retrospectively analyzed. Among them, 18 cases were treated with sacroiliac screws fixation assisted by 3D printed faceted honeycomb guide plate (guide plate group), and 22 cases were treated with sacroiliac screws percutaneously fixation under fluoroscopy (conventional group). There was no significant difference in baseline data ( P>0.05) such as gender, age, time from injury to operation, and Dennis classification between the two groups. The implantation time, frequency of C-arm X-ray fluoroscopy, frequency of guide pin adjustment of each sacroiliac screw, and postoperative complications and bone healing were recorded. Majeed score was used to evaluate the functional recovery at 6 months after operation, and CT was used to observe whether the screw penetrated the bone cortex. The deviation between the virtual position and the actual position of the screw tip, the sacral foramen, and the screw entry point was measured on the sagittal CT images of the guide plate group.

Results

The number of screws implanted in S 1 and S 2 vertebral bodies was 14 and 16 respectively in the guide plate group, and 17 and 18 respectively in the conventional group. The implantation time of each sacroiliac screw, the frequency of C-arm X-ray fluoroscopy, and the frequency of guide pin adjustment in S 1, S 2, and all vertebrae in the guide plate group were significantly less than those in the conventional group ( P<0.05). Patients in both groups were followed up 8-48 months, with an average of 19.7 months. There was no incision infection, screw displacement, or internal fixation loosening in both groups. Callus growth was observed in all patients at 12 weeks after operation, and bone healing was achieved in all patients. The healing time ranged from 12 to 24 weeks, with an average of 15.7 weeks. No sacroiliac screw penetrated the bone cortex in the guide plate group; 2 patients in the conventional group had sacroiliac screws penetrating the bone cortex without damaging blood vessels or nerves. In the guide plate group, the deviation between the virtual position and the actual position of the screw tip, the sacral foramen, and the screw entry point were (2.91±1.01), (2.10±0.74), and (1.67±0.70) mm, respectively, with an average deviation of (2.19±1.22) mm. There was no significant difference in Majeed function evaluation between the two groups at 6 months after operation ( P>0.05).

Conclusion

The application of 3D printed faceted honeycomb guide plate in sacroiliac screw implantation for posterior pelvic ring fracture can shorten the screw implantation time, reduce the frequency of fluoroscopy and guide pin adjustment, and reduce the risk of screw penetration through the bone cortex.

Mandibular bone segmentation from CT scans: Quantitative and qualitative comparison among software

OBJECTIVES

Nowadays, a wide variety of software for 3D reconstruction from CT scans is available; they differ for costs, capabilities, a priori knowledge, and, it is not trivial to identify the most suitable one for specific purposes. The article is aimed to provide some more information, having set up various metrics for the evaluation of different software's performance.

METHODS

Metrics include software usability, segmentation quality, geometric accuracy, mesh properties and Dice Similarity Coefficient (DSC). Five different software have been considered (Mimics, D2P, Blue Sky Plan, Relu, and 3D Slicer) and tested on four cases; the mandibular bone was used as a benchmark.

RESULTS

Relu software, being based on AI, was able to solve some very intricate geometry and proved to have a very good usability. On the other side, the time required for segmentation was significantly higher than other software (reaching over twice the time required by Mimics). Geometric distances between nodes position calculated by different software usually kept below 2.5 mm, reaching 3.1 mm in some very critical area; 75th percentile q75 is generally less than 0.5 mm, with a maximum of 1.11 mm. Dealing with consistency among software, the maximum DSC value was observed between Mimics and Slicer, D2P and Mimics, and D2P and Slicer, reaching 0.96.

SIGNIFICANCE

This work has demonstrated how mandible segmentation performance among software was generally very good. Nonetheless, differences in geometric accuracy, usability, costs and times required can be significant so that information here provided can be useful to perform an informed choice.

Systematic Review on the Use of 3D-Printed Models for Planning, Training and Simulation in Vascular Surgery

The use of 3D-printed models in simulation-based training and planning for vascular surgery is gaining interest. This study aims to provide an overview of the current applications of 3D-printing technologies in vascular surgery. We performed a systematic review by searching four databases: PubMed, Web of Science, Scopus, and Cochrane Library (last search: 1 March 2024). We included studies considering the treatment of vascular stenotic/occlusive or aneurysmal diseases. We included papers that reported the outcome of applications of 3D-printed models, excluding case reports or very limited case series (≤5 printed models or tests/simulations). Finally, 22 studies were included and analyzed. Computed tomography angiography (CTA) was the primary diagnostic method used to obtain the images serving as the basis for generating the 3D-printed models. Processing the CTA data involved the use of medical imaging software; 3DSlicer (Brigham and Women's Hospital, Harvard University, Boston, MA), ITK-Snap, and Mimics (Materialise NV, Leuven, Belgium) were the most frequently used. Autodesk Meshmixer (San Francisco, CA, USA) and 3-matic (Materialise NV, Leuven, Belgium) were the most frequently employed mesh-editing software during the post-processing phase. PolyJet™, fused deposition modeling (FDM), and stereolithography (SLA) were the most frequently employed 3D-printing technologies. Planning and training with 3D-printed models seem to enhance physicians' confidence and performance levels by up to 40% and lead to a reduction in the procedure time and contrast volume usage to varying extents.

Shaping the Future of Cardiovascular Disease by 3D Printing Applications in Stent Technology and its Clinical Outcomes

Cardiovascular disease (CVD) is a leading cause of death worldwide. In recent years, 3D printing technology has ushered in a new era of innovation in cardiovascular medicine. 3D printing in CVD management encompasses various aspects, from patient-specific models and preoperative planning to customized medical devices and novel therapeutic approaches. In-stent technology, 3D printing has revolutionized the design and fabrication of intravascular stents, offering tailored solutions for complex anatomies and individualized patient needs. The advantages of 3D-printed stents, such as improved biocompatibility, enhanced mechanical properties, and reduced risk of in-stent restenosis. Moreover, the clinical trials and case studies that shed light on the potential of 3D printing technology to improve patient outcomes and revolutionize the field has been comprehensively discussed. Furthermore, regulatory considerations, and challenges in implementing 3D-printed stents in clinical practice are also addressed, underscoring the need for standardization and quality assurance to ensure patient safety and device reliability. This review highlights a comprehensive resource for clinicians, researchers, and policymakers seeking to harness the full potential of 3D printing technology in the fight against CVD.

Advanced Strategies for the Fabrication of Multi-Material Anatomical Models of Complex Pediatric Oncologic Cases

The printing and manufacturing of anatomical 3D models has gained popularity in complex surgical cases for surgical planning, simulation and training, the evaluation of anatomical relations, medical device testing and patient-professional communication. 3D models provide the haptic feedback that Virtual or Augmented Reality (VR/AR) cannot provide. However, there are many technologies and strategies for the production of 3D models. Therefore, the aim of the present study is to show and compare eight different strategies for the manufacture of surgical planning and training prototypes. The eight strategies for creating complex abdominal oncological anatomical models, based on eight common pediatric oncological cases, were developed using four common technologies (stereolithography (SLA), selectie laser sinterning (SLS), fused filament fabrication (FFF) and material jetting (MJ)) along with indirect and hybrid 3D printing methods. Nine materials were selected for their properties, with the final models assessed for application suitability, production time, viscoelastic mechanical properties (shore hardness and elastic modulus) and cost. The manufacturing and post-processing of each strategy is assessed, with times ranging from 12 h (FFF) to 61 h (hybridization of FFF and SLS), as labor times differ significantly. Cost per model variation is also significant, ranging from EUR 80 (FFF) to EUR 600 (MJ). The main limitation is the mimicry of physiological properties. Viscoelastic properties and the combination of materials, colors and textures are also substantially different according to the strategy and the intended use. It was concluded that MJ is the best overall option, although its use in hospitals is limited due to its cost. Consequently, indirect 3D printing could be a solid and cheaper alternative.

New Insights and Advanced Strategies for In Vitro Construction of Vascularized Tissue Engineering

Inadequate vascularization is a significant barrier to clinical application of large-volume tissue engineered grafts. In contrast to in vivo vascularization, in vitro prevascularization shortens the time required for host vessels to grow into the graft core and minimizes necrosis in the core region of the graft. However, the challenge of prevascularization is to construct hierarchical perfusable vascular networks, increase graft volume, and form a vascular tip that can anastomose with host vessels. Understanding advances in in vitro prevascularization techniques and new insights into angiogenesis could overcome these obstacles. In the present review, we discuss new perspectives on angiogenesis, the differences between in vivo and in vitro tissue vascularization, the four elements of prevascularized constructs, recent advances in perfusion-based in vitro prevascularized tissue fabrication, and prospects for large-volume prevascularized tissue engineering.

Dental Material Selection for the Additive Manufacturing of Removable Complete Dentures (RCD)

This research addresses the development of a formalized approach to dental material selection (DMS) in manufacturing removable complete dentures (RDC). Three types of commercially available polymethyl methacrylate (PMMA) grades, processed by an identical Digital Light Processing (DLP) 3D printer, were compared. In this way, a combination of mechanical, tribological, technological, microbiological, and economic factors was assessed. The material indices were calculated to compare dental materials for a set of functional parameters related to feedstock cost. However, this did not solve the problem of simultaneous consideration of all the material indices, including their significance. The developed DMS procedure employs the extended VIKOR method, based on the analysis of interval quantitative estimations, which allowed the carrying out of a fully fledged analysis of alternatives. The proposed approach has the potential to enhance the efficiency of prosthetic treatment by optimizing the DMS procedure, taking into consideration the prosthesis design and its production route.