Application of 3D printing in early phase development of pharmaceutical solid dosage forms

Three-dimensional printing (3DP) is an emerging technology, offering the possibility for the development of dose-customized, effective, and safe solid oral dosage forms (SODFs). Although 3DP has great potential, it does come with certain limitations, and the traditional drug manufacturing platforms remain the industry standard. The consensus appears to be that 3DP technology is expected to benefit personalized medicine the most, but that it is unlikely to replace conventional manufacturing for mass production. The 3DP method, on the other hand, could prove well-suited for producing small batches as an adaptive manufacturing technique for enabling adaptive clinical trial design for early clinical studies. The purpose of this review is to discuss recent advancements in 3DP technologies for SODFs and to focus on the applications for SODFs in the early clinical development stages, including a discussion of current regulatory challenges and quality controls.

Trueness of five different 3D printing systems including budget- and professional-grade printers: An In vitro study

Problem

Several types of 3D printers with different techniques and prices are available on the market. However, results in the literature are inconsistent, and there is no comprehensive agreement on the accuracy of 3D printers of different price categories for dental applications.

Aim

This study aimed to investigate the accuracy of five different 3D printing systems, including a comparison of budget- and higher-end 3D printing systems, according to a standardized production and evaluation protocol.

Material and methods

A maxillary reference model with prepared teeth was created using 16 half-ball markers with a diameter of 1 mm to facilitate measurements. A reference file was fabricated using five different 3D printers. The printed models were scanned and superimposed onto the original standard tesselation language (.stl) file, and digital measurements were performed to assess the 3-dimensional and linear deviations between the reference and test models.

Results

After examining the entire surface of the models, we found that 3D printers using Fused filament fabrication (FFF) technology -120.2 (20.3) μm create models with high trueness but high distortion. Distortions along the z-axis were found to be the highest with the stereolithography (SLA)-type 3D printer at -153.7 (38.7) μm. For the 4-unit FPD, we found 201.9 (41.8) μm deviation with the digital light processing (DLP) printer. The largest deviation (-265.1 (55.4) μm) between the second molars was observed for the DLP printer. Between the incisor and the second molar, the best results were produced by the FFF printer with -30.5 (76.7) μm.

Conclusion

Budget-friendly 3D printers are comparable to professional-grade printers in terms of precision. In general, the cost of a printing system is not a reliable indicator of its level of accuracy.

Three-dimensional printed models can reduce costs and surgical time for complex proximal humeral fractures: preoperative planning, patient satisfaction, and improved resident skills

BACKGROUND

Proximal humeral fractures (PHFs) are still controversial with regards to treatment and are difficult to classify. The study's objective is to show that preoperative planning performed while handling a three-dimensional (3D) printed anatomical model of the fracture can ensure a better understanding of trauma for both surgeons and patients.

MATERIALS AND METHODS

Twenty patients (group A, cases) with complex PHF were evaluated preoperatively by reproducing life-size, full-touch 3D anatomical models. Intraoperative blood loss, radiographic controls, duration of surgery, and clinical outcomes of patients in group A were compared with 20 patients (group B, controls) who underwent standard preoperative evaluation. Additionally, senior surgeons and residents, as well as group A patients, answered a questionnaire to evaluate innovative preoperative planning and patient compliance. Cost analysis was evaluated.

RESULTS

Intraoperative radiography controls and length of operation were significantly shorter in group A. There were no differences in clinical outcomes or blood loss. Patients claim a better understanding of the trauma suffered and the proposed treatment. Surgeons assert that the planning of the definitive operation with 3D models has had a good impact. The development of this tool has been well received by the residents. The surgery was reduced in length by 15%, resulting in savings of about EUR 400 for each intervention.

CONCLUSIONS

Fewer intraoperative radiography checks, shorter surgeries, and better patient compliance reduce radiation exposure for patients and healthcare staff, enhance surgical outcomes while reducing expenses, and lower the risk of medicolegal claims.

LEVEL OF EVIDENCE

Level I, prospective randomized case-control study.

Reduced graphene oxide-reinforced tricalcium phosphate/gelatin/chitosan light-responsive scaffolds for application in bone regeneration

Bone is a mineralized tissue with the intrinsic capacity for constant remodeling. Rapid prototyping techniques, using biomaterials that mimic the bone native matrix, have been used to develop osteoinductive and osteogenic personalized 3D structures, which can be further combined with drug delivery and phototherapy. Herein, a Fab@Home 3D Plotter printer was used to promote the layer-by-layer deposition of a composite mixture of gelatin, chitosan, tricalcium phosphate, and reduced graphene oxide (rGO). The phototherapeutic potential of the new NIR-responsive 3D_rGO scaffolds was assessed by comparing scaffolds with different rGO concentrations (1, 2, and 4 mg/mL). The data obtained show that the rGO incorporation confers to the scaffolds the capacity to interact with NIR light and induce a hyperthermy effect, with a maximum temperature increase of 16.7 °C after under NIR irradiation (10 min). Also, the increase in the rGO content improved the hydrophilicity and mechanical resistance of the scaffolds, particularly in the 3D_rGO4. Furthermore, the rGO could confer an NIR-triggered antibacterial effect to the 3D scaffolds, without compromising the osteoblasts' proliferation and viability. In general, the obtained data support the development of 3D_rGO for being applied as temporary scaffolds supporting the new bone tissue formation and avoiding the establishment of bacterial infections.

Clinical situations for which 3D Printing is considered an appropriate representation or extension of data contained in a medical imaging examination: vascular conditions

BACKGROUND

Medical three-dimensional (3D) printing has demonstrated utility and value in anatomic models for vascular conditions. A writing group composed of the Radiological Society of North America (RSNA) Special Interest Group on 3D Printing (3DPSIG) provides appropriateness recommendations for vascular 3D printing indications.

METHODS

A structured literature search was conducted to identify all relevant articles using 3D printing technology associated with vascular indications. Each study was vetted by the authors and strength of evidence was assessed according to published appropriateness ratings.

RESULTS

Evidence-based recommendations for when 3D printing is appropriate are provided for the following areas: aneurysm, dissection, extremity vascular disease, other arterial diseases, acute venous thromboembolic disease, venous disorders, lymphedema, congenital vascular malformations, vascular trauma, vascular tumors, visceral vasculature for surgical planning, dialysis access, vascular research/development and modeling, and other vasculopathy. Recommendations are provided in accordance with strength of evidence of publications corresponding to each vascular condition combined with expert opinion from members of the 3DPSIG.

CONCLUSION

This consensus appropriateness ratings document, created by the members of the 3DPSIG, provides an updated reference for clinical standards of 3D printing for the care of patients with vascular conditions.

Assessment of knowledge, awareness and practices toward the use of 3D printing among dental laboratory technicians in Karnataka, India: A cross-sectional study

With the use of CAD/CAM technology and rapid prototyping, the opportunities for digitisation and technology are unlimited. 3D printing is going to revolutionise traditional teaching and laboratory methods with rapid progress of new materials, printing technology and machines. Given the large number of options available, one must keep up with the current and emerging technology in order to make benefit of the same. The aim of the study is to assess dental laboratory technicians' knowledge, understanding and practices related the use of 3D printing in dentistry in India.

Methods

From November 2021 to January 2022, a cross-sectional questionnaire-based study was done among dental laboratory technicians in India. Dental technicians were given access to a self-explanatory questionnaire via Google forms link consisting of 12 questions that evaluated their knowledge, awareness and practices regarding 3D printing. The CHERRIES protocol for presenting the findings of the survey was followed. Chi-square test and independent t-test was used for statistical analysis by SPSS version 20.0.

Results

A total of 191 responses were obtained after the questionnaire was circulated to 220 technicians. 171 dental technicians (89.53%) were acquainted of the usage of 3D printing in dentistry.169 (88.48%) Dental technicians preferred 3D printing to traditional procedures. Majority of dental technicians indicated they want to include the 3D printing into their regular work practices and believe digital technology will enhance our profession.

Conclusion

The level of awareness of digital dentistry and 3D printing among the participants is acceptable. Dental technicians at private laboratory showed better understanding about 3D printing as compared to technicians working at dental colleges nevertheless, dental education programmes, webinars and hands-on training should be undertaken that will enhance their expertise of 3D printing.

Computer-guided contouring of craniofacial fibrous dysplasia involving fronto-orbital or fronto-cranial region using patient specific surgical depth guide: A prospective case series

The aim of this study was to introduce a new computer guided technique for debulking and contouring the craniofacial fibrous dysplasia involving the fronto-orbital and fronto-cranial regions. Computer-guided contouring was performed using a modified patient-specific surgical depth guide for six patients with craniofacial fibrous dysplasia involving the fronto-orbital and fronto-cranial regions. Virtual planning was performed to determine the desired amount of bone removal and construct the patient-specific surgical depth guide. Then, the guide was printed using rapid prototyping. In the surgical theatre, the guide was seated in position. Implant drills were inserted through the created depth holes according to the planned fixed depth to create depth holes. Finally, the bone in between the created holes was removed using cutting discs, bone chisels and surgical burs. Satisfaction with facial aesthetics was evaluated by the patients using a Likert scale, and by the surgeons using the Whitaker rating scale. The surgical procedures were uneventful for all the patients. All the patients were satisfied with the post-operative facial esthetics and categorized as category I Whitaker rating scale. Patient-specific surgical guide technique for recontouring of fronto-orbital and fronto-cranial fibrous dysplasia can be considered an accurate substitution technique that overcomes the drawbacks of the unpredictable conventional one. Further investigations are required.

3D-printing a cost-effective model for mastoidectomy training

BACKGROUND

3D-printed temporal bone models can potentially provide a cost-effective alternative to cadaver surgery that can be manufactured locally at the training department. The objective of this study was to create a cost-effective 3D-printed model suitable for mastoidectomy training using entry level and commercially available print technologies, enabling individuals, without prior experience on 3D-printing, to manufacture their own models for basic temporal bone training.

METHODS

Expert technical professionals and an experienced otosurgeon identified the best material for replicating the temporal bone and created a cost-effective printing routine for the model using entry-level print technologies. Eleven participants at a temporal bone dissection course evaluated the model using a questionnaire.

RESULTS

The 3D-printed temporal bone model was printed using a material extrusion 3D-printer with a heat resistant filament, reducing melting during drilling. After printing, a few simple post-processing steps were designed to replicate the dura, sigmoid sinus and facial nerve. Modifying the 3D-printer by installing a direct-drive and ruby nozzle resulted in more successful prints and less need for maintenance. Upon evaluation by otorhinolaryngology trainees, unanimous feedback was that the model provided a good introduction to the mastoidectomy procedure, and supplementing practice to cadaveric temporal bones.

CONCLUSION

In-house production of a cost-effective 3D-printed model for temporal bone training is feasible and enables training institutions to manufacture their own models. Further, this work demonstrates the feasibility of creating new temporal bone models with anatomical variation to provide ample training opportunity.

Lignin-enriched tricalcium phosphate/sodium alginate 3D scaffolds for application in bone tissue regeneration

The bone is a connective, vascularized, and mineralized tissue that confers protection to organs, and participates in the support and locomotion of the human body, maintenance of homeostasis, as well as in hematopoiesis. However, throughout the lifetime, bone defects may arise due to traumas (mechanical fractures), diseases, and/or aging, which when too extensive compromise the ability of the bone to self-regenerate. To surpass such clinical situation, different therapeutic approaches have been pursued. Rapid prototyping techniques using composite materials (consisting of ceramics and polymers) have been used to produce customized 3D structures with osteoinductive and osteoconductive properties. In order to reinforce the mechanical and osteogenic properties of these 3D structures, herein, a new 3D scaffold was produced through the layer-by-layer deposition of a tricalcium phosphate (TCP), sodium alginate (SA), and lignin (LG) mixture using the Fab@Home 3D-Plotter. Three different TCP/LG/SA formulations, LG/SA ratio 1:3, 1:2, or 1:1, were produced and subsequently evaluated to determine their suitability for bone regeneration. The physicochemical assays demonstrated that the LG inclusion improved the mechanical resistance of the scaffolds, particularly in the 1:2 ratio, since a 15 % increase in the mechanical strength was observed. Moreover, all TCP/LG/SA formulations showed an enhanced wettability and maintained their capacity to promote the osteoblasts' adhesion and proliferation as well as their bioactivity (formation of hydroxyapatite crystals). Such results support the LG inclusion and application in the development of 3D scaffolds aimed for bone regeneration.

Computer Guided Generated Dual-Purpose Splint for Bilateral Sagittal Split Osteotomy

Purpose

to evaluate the efficacy of dual-purpose computer-generated splint in guiding the proximal and the distal segment in bilateral sagittal split osteotomy.

Patients and Method

It was a prospective case series study directed on 8 class III patients indicating the need of maxillary advancement and mandibular set back by bilateral sagittal split osteotomy. A CAD/CAM splint is generated to guide the distal segment to the stable maxilla and at the same time a grooved extension to engage the proximal segment ensuring the condyle in its planned position during fixation. The primary outcome was measured by calculating the difference between the pre- and post-operative condylar segment position.

Results

The present study included five female patient and three male patient with mean age of 28.4 ± 5.1 years. The accuracy of the splint in positioning the mandibular proximal segment showed promising results ranging from 2.59 to 0.49.

Conclusion

The dual-purpose splint introduced in this study showed satisfied results in maintaining the pre-operative condylar position while securing the distal segment in the desired plan.

Assessment of knowledge, awareness, and practices toward the use of 3D printing in dentistry among dental practitioners and dental technicians: A cross-sectional study

Background

The applications and scope of digitization and technology in dentistry are becoming increasingly valuable right from clinical dentistry to research, student training, teaching, and laboratory techniques. Mastering 3D printing and its usage are essential for dental practitioners and dental technicians as it allows them to choose and necessarily know what is offered, as well as how to implement it in everyday practices thereby contributing to the betterment of the dental profession. The study aims to assess dental practitioners' and dental technicians' knowledge, understanding, and practices related to the use of 3D printing in dentistry.

Methods

A cross-sectional questionnaire-based study was done among dental practitioners and technicians in Karnataka, India who were given access to a self-explanatory questionnaire via Google link consisting of questions that evaluated their knowledge, awareness, and practices regarding 3D printing. The Chi-square test was used for statistical analysis.

Results

A total of 380 replies were obtained after the questionnaire was circulated. Awareness regarding the use of digital technology in dentistry was known by 98.9% of practitioners and 92.7% of technicians, of which we discovered that 9.28% of practitioners and 17.7% of technicians were unfamiliar with 3D printing, which was statistically significant (p = 0.0400*). 81.6% of practitioners consider 3D printing can be used to fabricate complex design prostheses.

Conclusion

The participants' understanding of digital dentistry and 3D printing is acceptable. The majority of dental professionals expressed an interest in adopting 3D printing and believe that there should be a forum for collecting and exchanging skills and knowledge about 3D printing.

Robustness optimization for rapid prototyping of functional artifacts based on visualized computing digital twins

This study presents a robustness optimization method for rapid prototyping (RP) of functional artifacts based on visualized computing digital twins (VCDT). A generalized multiobjective robustness optimization model for RP of scheme design prototype was first built, where thermal, structural, and multidisciplinary knowledge could be integrated for visualization. To implement visualized computing, the membership function of fuzzy decision-making was optimized using a genetic algorithm. Transient thermodynamic, structural statics, and flow field analyses were conducted, especially for glass fiber composite materials, which have the characteristics of high strength, corrosion resistance, temperature resistance, dimensional stability, and electrical insulation. An electrothermal experiment was performed by measuring the temperature and changes in temperature during RP. Infrared thermographs were obtained using thermal field measurements to determine the temperature distribution. A numerical analysis of a lightweight ribbed ergonomic artifact is presented to illustrate the VCDT. Moreover, manufacturability was verified based on a thermal-solid coupled finite element analysis. The physical experiment and practice proved that the proposed VCDT provided a robust design paradigm for a layered RP between the steady balance of electrothermal regulation and manufacturing efficacy under hybrid uncertainties.

A Review of the Use of 3D Printing Technology in Treatment of Scaphoid Fractures

Background: Three-dimensional (3D) printing technology is increasingly commercially viable for pre-surgical planning, intraoperative templating, jig creation and customised implant manufacture. The challenging nature of scaphoid fracture and nonunion surgery make it an obvious target. The aim of this review is to determine the use of 3D printed technologies in the treatment of scaphoid fractures. Methods: This is a review of the Medline, Embase and Cochrane Library databases examining studies aimed at therapeutic use of 3D printing, also known as rapid prototyping or additive technology, in the treatment of scaphoid fractures. All studies published up to and including November 2020 were included in the search. Relevant data extracted included modality of use (as template/model/guide/prosthesis), operative time, accuracy of reduction, radiation exposure, follow-up duration, time to union, complications and study quality. Results: A total of 649 articles were identified, of which 12 met the full inclusion criteria. Analysis of the articles showed that 3D printing techniques can be utilised in myriad ways to aid planning and delivery of scaphoid surgery. Percutaneous guides for Kirschner-wire (K-wire) fixation of non-displaced fractures can be created; custom guides can be printed to aid reduction of displaced or non-united fractures; patient-specific total prostheses may recreate near-normal carpal biomechanics and a simple model may help graft harvesting and positioning. Conclusions: This review found that the use of 3D printed patient-specific models and templates in scaphoid surgery can improve accuracy and speed, and reduce radiation exposure. 3D printed prostheses may also restore near-normal carpal biomechanics without burning bridges for potential future procedures. Level of Evidence: Level III (Therapeutic).

Research relating to three-dimensional (3D) printing in spine surgery: a bibliometric analysis

PURPOSE

Although numerous publications on three-dimensional printing (3DP) in spine surgery have been published, bibliometric analysis studies are scarce. Thus, this study aimed to present a bibliometric analysis of the status, hot spots, and frontiers of 3DP in spine surgery and associated research disciplines.

METHODS

All publications relating to the utilization of 3DP in spine surgery from 1999 to May 9, 2022, were retrieved from the Web of Science. The bibliometric analysis was performed using CiteSpace software, and information on the country, institution, author, journal, and keywords for each publication was collected.

RESULTS

A total of 270 articles were identified. From 2016 onward, a significant increase in publications on spinal surgery was observed. China was the most productive and influential country (98 publications) and H-index (22), followed by the USA and Australia. The most productive institution was Capital Medical University (9 publications). P. S. D'urso (8 publications, 46 citations) and R. J. Mobbs (8 publications, 39 citations) were the most prolific authors. European Spine Journal contributed the highest number of publications. The eight main clusters were: "rapid prototyping" #0, "3D printed" #1, "spine fusion" #2, "scoliosis" #3, "spine surgery" #4, "patient-specific" #5, "nervous system" #6, and "neuronavigation" #7. The strongest keyword bursts in 3DP in spine surgery were "fixation," "drill template," "instrumentation," "fusion," "complication," and "atlantoaxial instability."

CONCLUSION

This analysis provides information on research trends and frontiers in the application of 3DP in spine surgery, as well as research and collaboration partners, institutions, and countries.

Total mandible and bilateral TMJ reconstruction combining a customized jaw implant with a free fibular flap: a case report and literature review

BACKGROUND

The need for whole mandibular bone reconstruction and bilateral joint replacement is fortunately rare, but it is an extremely challenging topic in maxillofacial surgery, due to its functional implications. CAD-CAM techniques development has opened new broad horizons in the surgical planning of complex maxillofacial reconstructions, in terms of accuracy, predictability, and functional cosmetic results. The review of the literature has revealed a small number of scientific reports on total mandibulectomy including the condyles, with only eleven cases from 1980. Most of the works describe reconstructions secondary to dysplastic or inflammatory diseases affecting the lower jaw. The aim of this work, reporting a rare case of massive fibrous dysplasia of the whole mandible, is to share our experience in the management of extended mandibular and bilateral joint reconstruction, using porous titanium patient-specific implants.

CASE PRESENTATION

The authors present a 20-year-old male patient suffering from massive bone fibrous dysplasia of the mandible. The mandibular body and both the rami and the condylar processes had been involved, causing severe functional impairment, tooth loss, and facial deformation. The young patient, after repeated ineffective conservative surgical treatments, has required a biarticular mandibular replacement. Using virtual surgical planning (VSP) software, the authors, in collaboration with medical engineers, have created a custom-made original titanium porous mandibular implant, suspended from a bilateral artificial temporomandibular joint. The mandibular titanium implant body has been specifically designed to support soft tissues and to fix, in the alveolar region, a free fibular bone graft, for delayed dental implant prosthetic rehabilitation.

CONCLUSION

The surgical and technical details, as well as the new trends in mandibular reconstructions using porous titanium implants, are reported, and discussed, reviewing literature reports on this topic. Satisfactory functional and cosmetic restorative results have been obtained, and no major complications have occurred. The patient, currently in the 18^th month clinical and radiological follow-up, has recently completed the functional restoration program by an implant-supported full-arch dental prosthesis.

Instructional Design for Socially Distanced Compliance Audit

The COVID-19 pandemic made being socially distant an essential practice to upskill employees. As employers incorporate measures to keep employees socially distant from one another, they also need to consider technology to make this practice possible. Our project with a large state-wide, multi-campus food bank (FB) in the pacific northwest occurred during the late summer and early fall of 2020. The FB partnered with our group of three graduate students and one faculty member to improve self-audits of their coolers. This project used technology and rapid prototyping to design an instructional intervention that allowed social distancing in a workplace where employees were required to be present. We conducted a front-end analysis including training requirements, learner and environmental analysis and task analysis. This article describes the process of the analyses and design of instructional materials that allowed the FB to scale their audit process to their other warehouses.

3D printing in spine care: A review of current applications

3D printing (3DP) has been brought to medical use since the early part of this century- but it has been widely researched on and publicized only in the last few years. Amongst patients with spinal disorders, 3DP has been utilized in various facets of patient care. These include pre-operative aspects - such as patient education, resident training, pre-operative planning and simulations, intra-operative assistance in the form of customized jigs for pedicle screw insertion, patient specific interbody cages and vertebral body substitutes in complex malignancies and spinal infections. It has also been utilized in deformity surgeries and has opened new avenues in minimally invasive spine care. Guidelines have now been drafted by various organizations including the FDA with a prime focus on quality control measures applicable to this new technology. There has been a recent surge in publications supporting the use of 3DP in spinal disorders, reporting an improvement in various aspects of patient care. As the technology spreads out its wings further, more innovations and applications are expected to unfold in the coming years. Considering the rapid advances that 3DP has made, having a basic understanding of this technology is imperative for all spine surgeons. Despite promising preliminary results, there still exist a few pitfalls of the technology which have hindered the universal application of 3DP. Most importantly, there is a dearth of data related to long term outcomes supporting its clinical use. The prohibitive cost of 3D models, the specialized manpower it necessitates and the need for specific instrumentation are major deterrents to widespread use of this technology, particularly in small-scale healthcare setups. With further advancements in technology, the goal must be to make it more accurate and affordable to hospitals and patients so that the benefits of the technology can reach a wider patient population.

Comparison of Dimensional Changes Between CAD-CAM Milled Complete Denture Bases and 3D Printed Complete Denture Bases: An In Vitro Study

PURPOSE

This study compared the dimensional changes between the computer-aided design and computer-aided manufacturing (CAD-CAM) milled complete denture bases (CDBs) and three-dimensional (3D) printed CDBs.

MATERIALS AND METHODS

One maxillary completely edentulous stone model was fabricated with three reference points at the incisive papilla, right molar, and left molar areas marked as X, Y, and Z, respectively. It was scanned to produce a standard tessellation language (STL) file, which was imported to a metal milling machine software to produce the metal model. This metal model was used to fabricate 30 CDBs for analysis in this study. The CDBs were divided into three groups (n = 10 each) according to the fabrication method used as follows: Group 1, CAD-CAM milled CDBs; Group 2, 3D printed CDBs; and Group 3, conventional compression molded CDBs. The CDBs of all groups were scanned after fabrication, and the dimensional changes in each were evaluated by two methods. The first was the two-dimensional evaluation method that involved linear measurement of the distances between the reference points (X-Y, X-Z, and Y-Z) of the scanned reference cast and dentures. The second method was the 3D evaluation method that involved the superimposition of the STL files of the dentures on the STL file of the reference cast. Data were calculated and were statistically analyzed using one-way analysis of variance and Tukey's pairwise post hoc tests.

RESULTS

There was a significant difference in the dimensional accuracy between the CAD-CAM milled, 3D printed, and conventional compression molded CDBs (P<0.05).

CONCLUSION

The dimensional accuracy of the CAD-CAM milling system in complete denture fabrication is superior to that of the compression molding and 3D printing systems. This article is protected by copyright. All rights reserved.

Patient-specific PEEK implants for immediate restoration of temporal fossa after maxillary reconstruction with temporalis muscle flap

BACKGROUND

Temporal hollowing is a common complication following the rotation of the temporalis muscle that leaves the patient with a cosmetic impairment. Several alloplastic materials have been used to reconstruct the donor site; however, these implants need meticulous adaptation to conform the periphery of the defect and restore the contour of the temporal area. The aim of this study was to assess the use of patient-specific polyetheretherketone (PEEK) temporal implants to prevent temporal hollowing following the use of full temporalis muscle flap for large maxillary defects reconstruction.

METHODS

This was a prospective study conducted on eight patients with major maxillary defects indicating the need of reconstruction with full temporalis muscle flap or any lesion indicating major maxillary resection and immediate reconstruction with total temporalis muscle flap. For each patient, a patient-specific PEEK implant was fabricated using virtual planning and milled from PEEK blocks. In the surgical theater, the temporalis muscle was exposed, elevated, and transferred to the maxilla. After the temporalis muscle transfer, PEEK implants were fixed in place to prevent temporal hollowing.

RESULTS

The surgical procedures were uneventful for all patients. The esthetic result was satisfactory with no post-operative complications except in one patient where seroma occurred after 2 weeks and resolved after serial aspiration.

CONCLUSION

Patient-specific PEEK implant appears to facilitate the surgical procedures eliminate several meticulous steps that are mainly based on the surgeon's experience.

TRIAL REGISTRATION

Clinical trials registration: NCT05240963 .

Reconsidering some standards in immediate autotransplantation of teeth: Case report with 2-year follow-up

Introduction

Dental autotransplantation (DAT) is that surgical procedure of extracting a tooth from one place (donor site) and transplanting it into another (recipient site) within the same individual. If successfully implemented, the treatment outcome will pose characteristics of a natural tooth rather than a dental prosthesis. This case report sheds light on the validity of this treatment option, and provides suggestions to reconsider some standards regarding its conventional protocols.

Case presentation

A 24-year-old female with no history of medical conditions presented with hopelessnon-restorable lower molars with clinical signs of chronic infection. Cone-beam computed tomography (CBCT) was used to check compatibility of her third molars for DAT. After clinical and radiographical examination, patient's consent to perform DAT of impacted upper right third molar to replace the lower right first molar was obtained. Based on patient's CBCT, an individual replica of the donor tooth was fabricated. Replica helped in pre-preparing recipient site to fit the dimensions of the donor tooth before being extracted and transplanted. The extraction socket was thoroughly debrided and irrigated to ensure the removal of any lesion or infection. Immediate DAT was carried out with minimal trauma to the transplant. Follow-up for 2 years showed functional transplant with uneventful healing of periodontal and pulpal tissues.

Conclusion

Some standards regarding DAT needs to be reconsidered. Routine prophylactic endodontic treatment is not necessary for every case of DAT even when transplanted tooth is mature. Immediate autotransplantation into an infected site can be successful if the recipient site is managed properly.

Cell-Free Protein Synthesis Using Pichia pastoris

Pichia pastoris (syn. Komagataella phaffii) is an industrially relevant recombinant protein platform that has been used to produce over 5000 proteins to date. Cell-free protein synthesis can be used as a screening tool before strain development or for the production of proteins that are difficult or toxic to make in vivo. Here we describe the methods for generating an active cell lysate from P. pastoris using high pressure homogenization and an improved reaction mix which results in high yields of reporter proteins such as luciferase, and complex proteins such as human serum albumin and virus-like particles.

Open source anaerobic and temperature-controlled in vitro model enabling real-time release studies with live bacteria

In vitro release and dissolution models are widely used in the development phases of oral drug delivery systems to measure how an active pharmaceutical ingredient (API) is released from a dosage form. However, additional requirements for these models arise when evaluating probiotic dosage forms since they are often sensitive to temperature and oxygen levels. As a solution to this, we propose a custom-designed anaerobic in vitro release setup, made mainly by 3D printing and laser cutting, to function together with state-of-the-art pharmaceutical dissolution equipment - in this case, a microDISS Profiler™. The in vitro release model makes it possible to study the release rate of oxygen-sensitive probiotics in simulated intestinal conditions, while ensuring their survival due to the anaerobic conditions. This has not been possible so far since the available in vitro dissolution models have not been compatible with anaerobic conditions. With two different case studies, the developed model combined with a microDISS Profiler™ has proven capable of measuring the release of a probiotic and a small-molecule API from microdevices for oral drug delivery. Further, the model facilitated the survival of anaerobic bacteria present in the release medium.

Design and experimental testing of a force-augmenting exoskeleton for the human hand

Background

Many older Americans suffer from long-term upper limb dysfunction, decreased grip strength, and/or a reduced ability to hold objects due to injuries and a variety of age-related illnesses. The objective of this study was to design and build a five-fingered powered assistive exoskeleton for the human hand, and to validate its ability to augment the gripping and pinching efforts of the wearer and assist in performing ADLs.

Methods

The exoskeleton device was designed using CAD software and 3-D printed in ABS. Each finger’s movement efforts were individually monitored by a force sensing resistor at each fingertip, and proportionally augmented via the microcontroller-based control scheme, linear actuators, and rigid exoskeleton structure. The force production of the device and the force augmenting capability were assessed on ten healthy individuals with one 5-digit grasping test, three pinching tests, and two functional tests.

Results

Use of the device significantly decreased the forearm muscle activity necessary to maintain a grasping effort (67%, p < 0.001), the larger of two pinching efforts (30%, p < 0.05), and the palmer pinching effort (67%, p < 0.001); however, no benefit by wearing the device was identified while maintaining a minimal pinching effort or attempting one of the functional tests.

Conclusion

The exoskeleton device allowed subjects to maintain independent control of each digit, and while wearing the exoskeleton, in both the unpowered and powered states, subjects were able to grasp, hold, and move objects such as a water bottle, bag, smartphone, or dry-erase marker.

Rapid prototyping-assisted tooth autotransplantation is associated with a reduced root canal treatment rate: a retrospective cohort study

Background

Autotransplantation is a beneficial treatment with a high success rate for young patients. However, most adult patients require root canal treatment (RCT) of the donor teeth after the autotransplantation procedure, which causes a prolonged treatment time and additional expenses and increases the rate of future tooth fracture. Rapid prototyping (RP)-assisted autotransplantation shortens the extra-alveolar time and enables a superior clinical outcome. However, no cohort studies of the application of this method on adult populations have been reported.

Methods

This study is a retrospective cohort study. All patients underwent autotransplantation from 2012 to 2020 in the Kaohsiung and Chia-Yi branches of Chang Gung Memorial Hospital, and the procedure and clinical outcomes were analysed. Differences in clinical outcomes, age, sex, extra-alveolar time, fixation method, and RCT rate were compared between the two groups.

Results

We enrolled 21 patients, 13 treated using the conventional method and 8 treated using the RP-based technique. The RCT rates of the conventional group and RP group were 92.3% and 59%, respectively. The mean age of the two groups was significantly different (28.8 ± 10 vs. 21.6 ± 2.1); after performing subgroup analysis by excluding all of the patients aged > 40 years, we found that the RCT rates were still significantly different (91.0% vs. 50%). The mean extra-alveolar time was 43 s in the RP group, and the autotransplantation survival rate in both groups was 100%.

Conclusions

Rapid prototyping-assisted autotransplantation was successfully adopted for all patients in our study population. By shortening the extra-alveolar time, only 50% of the patients required a root canal treatment with a 100% autotransplantation survival rate.

Trial Registration : Retrospectively registered.

Effectiveness of digital data acquisition technologies in the fabrication of maxillofacial prostheses - A systematic review

Objective

The systematic review was designed to review and analyze the outcomes of various digital data acquisition technologies used for treatment planning in the prosthetic rehabilitation of maxillofacial defects.

Methods

The review protocol was registered in PROSPERO data with registration number: CRD42020188415. The PICOS inclusion criteria was employed in the systematic review. An electronic search (PubMed, databases) yielded twenty-eight eligible case reports. The qualitative methodological assessment was done according to an article that provided criteria for special considerations in evaluating case reports. It consisted of four questions, each carrying grading of 0, 1, and 2. During the full-text screening, the reviewers shortlisted six outcomes (time, aesthetics, cost, dimensional accuracy, patient satisfaction, and fabrication process) and graded (0, 1, 3) according to the outcomes they met.

Results

The majority of the included case reports used LASER scanners. Auricular and orbital defects were the highest reported cases. In nasal and orbital defects, the mean outcome of the shorter time required for the fabrication was the highest. In auricular prostheses, the mean outcome of dimensional accuracy was highest. In facial prostheses, aesthetics, dimensional accuracy, and patient satisfaction had the highest mean outcome whereas, in obturators, the shorter time required, dimensional accuracy, and patient satisfaction had the highest mean outcome. A total of 18 studies were graded as highly significant studies according to the methodological qualitative assessment.

Conclusion

LASER scanning systems in nasal prostheses, LASER scanners and combination of CT scan and digital photography in auricular prostheses, digital photography and stereophotogrammetry in case of large facial defects and combination of MRI and CT scan for obturators appeared to be a superior method of digital data acquisition.

Novel glass capillary microfluidic devices for the flexible and simple production of multi-cored double emulsions

HYPOTHESIS

Double emulsions with many monodispersed internal droplets are required for the fabrication of multicompartment microcapsules and tissue-like synthetic materials. These double emulsions can also help to optically resolve different coalescence mechanisms contributing to double emulsion destabilization. Up to date microfluidic double emulsions are limited to either core-shell droplets or droplets with eight or less inner droplets. By applying a two-step jet break-up within one setup, double emulsion droplets filled with up to several hundred monodispersed inner droplets can be achieved.

EXPERIMENTS

Modular interconnected CNC-milled Lego®-inspired blocks were used to create two separated droplet break-up points within coaxial glass capillaries. Inner droplets were formed by countercurrent flow focusing within a small inner capillary, while outer droplets were formed by co-flow in an outer capillary. The size of inner and outer droplets was independently controlled since the two droplet break-up processes were decoupled.

FINDINGS

With the developed setup W/O/W and O/W/O double emulsions were produced with different surfactants, oils, and viscosity modifiers to encapsulate 25-400 inner droplets in each outer drop with a volume percentage of inner phase between 7% and 50%. From these emulsions monodispersed multicompartment microcapsules were obtained. The report offers insights on the relationship between the coalescence of internal droplets and their release.

An open-source powered and ergonomic personal protective respirator for frontline COVID-19 response

Intending to shield front-liners who are currently exposed to COVID-19, and because of the lack of proper powered air-purifying respirator, this study shows the design and development of an open-source ergonomic respirator with a washable filter. This device has an estimated working time of 12 h, and the tests' airflow always showed a value over 4.5 cubic feet per minute, a higher value than the national institute for occupational safety and health specification for full-face closed respirators. The proposal relies on 3D printing technology for all the custom-design parts and usages easy-to-access components for the rest of the material. The mask for the APRPAPR in the article has a defogging feature, 180 degrees of viewing angle, an ergonomic profile, and no obstruction on the mouth to show the user's full face. This respirator has an estimated cost of 318 USD, approximately one-third of the market's price of well-known brands.

Open-source hybrid 3D-bioprinter for simultaneous printing of thermoplastics and hydrogels

3D-bioprinting is a promising technology applicable in areas such as regenerative medicine or in vitro organ model development. Various 3D-bioprinting technologies and systems have been developed and are partly commercially available. Here, we present the construction and characterization of an open-source low-cost 3D-bioprinter that allows the alternated microextrusion of hydrogel and fused deposition modeling (FDM) of thermoplastic filaments. The presented 3D-bioprinter is based on a conventional Prusa i3 MK3 printer and features two independent printheads: the original FDM-head and a syringe-based microextrusion printhead for soft materials. Modifications were designed modularly to fit various syringe formats or heating elements to the device. The bioprinter is the first hybrid DIY 3D-bioprinter that allows switching between materials as often as required during a print run to produce complex multi-material constructs with arbitrary patterns in each layer. For validation of the printer, two designs suitable for relevant bioprinting applications were realized. First, a porous plastic construct filled with hydrogel was printed, serving as a mechanically stable bone replacement tissue model. Second, a plastic chamber, which might be used in organ-on-a-chip applications, was printed with an extruded silicone sealing that enables the liquid-tight attachment of glass slides to the top and bottom of the chamber.

Determining tolerance levels for quality assurance of 3D printed bolus for modulated arc radiotherapy of the nose

Given the existing literature on the subject, there is obviously a need for specific advice on quality assurance (QA) tolerances for departments using or implementing 3D printed bolus for radiotherapy treatments. With a view to providing initial suggested QA tolerances for 3D printed bolus, this study evaluated the dosimetric effects of changes in bolus geometry and density, for a particularly common and challenging clinical situation: specifically, volumetric modulated arc therapy (VMAT) treatment of the nose. Film-based dose verification measurements demonstrated that both the AAA and the AXB algorithms used by the Varian Eclipse treatment planning system (Varian Medical Systems, Palo Alto, USA) were capable of providing sufficiently accurate dose calculations to allow this planning system to be used to evaluate the effects of bolus errors on dose distributions from VMAT treatments of the nose. Thereafter, the AAA and AXB algorithms were used to calculate the dosimetric effects of applying a range of simulated errors to the design of a virtual bolus, to identify QA tolerances that could be used to avoid clinically significant effects from common printing errors. Results were generally consistent, whether the treatment target was superficial and treated with counter-rotating coplanar arcs or more-penetrating and treated with noncoplanar arcs, and whether the dose was calculated using the AAA algorithm or the AXB algorithm. The results of this study suggest the following QA tolerances are advisable, when 3D printed bolus is fabricated for use in photon VMAT treatments of the nose: bolus relative electron density variation within [Formula: see text] (although an action level at [Formula: see text] may be permissible); bolus thickness variation within [Formula: see text] mm (or 0.5 mm variation on opposite sides); and air gap between bolus and skin [Formula: see text] mm. These tolerances should be investigated for validity with respect to other treatment modalities and anatomical sites. This study provides a set of baselines for future comparisons and a useful method for identifying additional or alternative 3D printed bolus QA tolerances.

Cell-free protein synthesis using Chinese hamster ovary cells

Cell-free protein synthesis (CFPS) platforms can be used for rapid and flexible expression of proteins. The use of CFPS platforms from mammalian, specifically Chinese hamster ovary (CHO) cells, offers the possibility of a rapid prototyping platform for recombinant protein production with the capabilities of post-translational modifications. In this chapter, we discuss a refined CFPS system based on CHO cells, including: extract preparation, reaction mix composition, and accessory protein supplementation to enhance expression. Specifically, when the CHO cell extract is combined with a truncated version of GADD34 and K3L, stress-induced eIF2 phosphorylation is reduced and inhibition of translation initiation is relieved, increasing yields. A brief summary of the protocol for running the CFPS reactions is also described. Overall, the method is reliable and leads to a highly reproducible expression system. Finally, the advantages and disadvantages of the platform, in addition to expected outcomes, are also discussed.

Use of 3D printed connectors to redesign full face snorkeling masks in the COVID-19 era: A preliminary technical case-study

The COVID-19 pandemic resulted in severe shortages of personal protection equipment and non-invasive ventilation devices. As traditional supply chains could not meet up with the demand, makeshift solutions were developed and locally manufactured by rapid prototyping networks. Among the different global initiatives, retrofitting of full-face snorkeling masks for Non-Invasive-Ventilation (NIV) applications seems the most challenging. This article provides a systematic overview of rapid prototyped - 3D printed - designs that enable attachment of medical equipment to snorkeling masks, highlighting potential and challenges in additive manufacturing. The different NIV connector designs are compared on low-cost 3D fabrication time and costs, which allows a rapid assessment of developed connectors for health care workers in urgent need of retrofitting snorkeling masks for NIV purposes. Challenges and safety issues of the rapid prototyping approach for healthcare applications during the pandemic are discussed as well. When critical parameters such as the final product cost, geographical availability of the feedstock and the 3D printers and the medical efficiency of the rapid prototyped products are well considered before deploying decentralized 3D printing as manufacturing method, this rapid prototyping strategy contributed to reduce personal protective equipment and NIV shortages during the first wave of the COVID-19 pandemic. It is also concluded that it is crucial to carefully optimize material and printer parameter settings to realize best fitting and airtight connector-mask connections, which is heavily depending on the chosen feedstock and type of printer.

Investigating the mechanical and optical properties of novel Urethandimethacrylate (UDMA) and Urethanmethacrylate (UMA) based rapid prototyping materials

OBJECTIVE

This study is focused on testing experimental rapid prototyping materials for occlusal splints made from Urethandimethacrylate (UDMA) and Urethanmethacrylate (UMA).

METHODS

Materials were mixed from UDMA and UMA in ratios of 1.0:0.0, 0.75:0.25, 0.5:0.5, 0.25:0.75 and 0.0:1.0. Specimens were printed using digital light processing (DLP). After post-processing, the specimens underwent testing on flexural strength, modulus of elasticity, hardness, wear behavior, surface roughness, gloss and color stability. All tests were performed after 24 h (baseline) and 10 days of water storage (aging). Splints underwent cyclic pull-off and insertion testing, which was alongside simulated using finite element analysis.

RESULTS

The mechanical properties were significantly influenced by changes in the UDMA:UMA ratio. Statistical analysis revealed that increased amounts of UMA correlated with a decrease in flexural strength (92.0 to 30.7 MPa), modulus of elasticity (2.4 to 0.6 GPa), hardness (155.1 to 102.0 N/mm²) and wear resistance (-1394.9 to -1742.1 μm). Materials with higher amounts of UMA were also more likely to be influenced by water storage. Specimens with 75% and 100% UMA content were partly not analyzable due to soft consistency. Optical properties showed only minor influence from UMA content and aging. Differences in surface roughness (3.9 to 2.4 μm) and color stability were insignificant. Gloss was partly influenced by the UDMA:UMA ratio and water storage. Mean survival rates for cyclic pull-off and insertion testing ranged from 2537 to 23,857 cycles. A correlation between the amount of UMA and survival rates was observed.

SIGNIFICANCE

The addition of up to 25% UMA showed promising results, complying with clinical standards and delivering acceptable results in the cyclic pull-off and insertion test. Further investigation on increments between 0 and 25% UMA could help to find an optimum.

Comparison of 3D Printing Rapid Prototyping Technology with Traditional Radiographs in Evaluating Acetabular Defects in Revision Hip Arthroplasty: A Prospective and Consecutive Study

Objective

To compare rapid prototyping technology (RP tech) in revision total hip arthroplasty (RTHA) with traditional examination methods and to see how they are different in evaluating acetabular anatomy and designing surgical procedure.

Methods

From February 2014 to March 2018, 43 RTHA patients with complex acetabulum defects were enrolled in this prospective study regardless of age or gender. Incomplete and unclear data were excluded. Three types of radiographic examination were performed on each patient before the revision surgery. Four groups of evaluations were designed: (i) X‐ray; (ii) computed tomography (CT‐scan); (iii) RP tech; and (iv) CT‐aided RP tech. Discrepancies between preoperative radiographic analysis and intra‐operative findings were separately compared by a team of surgeons. Premade surgical plans based on each evaluation method were compared with the final surgical procedure. The compliance of anatomic evaluation and surgical plan‐design based on 3D RP tech and traditional radiographs were ranked manually by a of team surgeons into: (i) complete accordance; (ii) general accordance; and (iii) undetermined structure/procedure. The difference in ranks between RP tech and traditional radiographic methods were analyzed with a nonparametric Kruskal‐Wallis test. P < 0.05 was considered significant. Multiple adjustments were taken for the statistical tests level according to the Bonferroni method.

Results

For anatomic analysis, the accordance in four groups of evaluating methods differed from each other (P < 0.05) except for the comparison of RP tech and CT‐aided RP tech. RP tech displayed better anatomic evaluating accuracy than traditional methods (X‐ray and CT) with the “complete accordance” rates of these groups being 88.37%, 4.65% and 27.91%, respectively. But CT‐aided RP tech did not improve accuracy significantly compared with using RP tech individually, although the value seems high in the CT‐aided RP group with the “complete accordance” rate of 95.35%. For surgery design, RP tech significantly showed better applicable surgical design compared with X‐ray and CT (P < 0.05), and the “complete accordance” rates were 88.37%, 6.98% and 23.26%, but no significant difference was observed between RP tech and CT‐aided RP tech, and the “complete accordance” rate of CT‐aided RP tech group was 97.67%. RP tech showed remarkable improvement in bone defect assessment and surgical plan design.

Conclusion

Using RP technology improved both sensibility and accuracy in acetabular defect evaluation with better locating and evaluating efficiency compared with X‐ray and CT‐scans. It also improved surgical schedule designing in complex acetabular defecting revision surgery. In particularly complex cases, CT aided RP tech may increase the accuracy of RP tech.

Needle penetration test - qualifying examination of 3D printable silicones for vascular models in surgical practice

Background

During cardiogenic shock blood circulation is minimal in the human body and does not suffice to survive. The extracorporeal life support system (ECLS) acts as a miniature heart-lung-machine that can be temporarily implanted over major vessels e.g. at the groin of the patient to bridge cardiogenic shock. To perform this procedure in an emergency, a proper training model is desirable. Therefore, a 3-dimensional-printable (3D) material must be found that mimics large vessel needle penetration properties. A suitable test bench for material comparison is desirable.

Methods

A test setup was built, which simulated the clinically relevant wall tension in specimens. The principle was derived from an existing standardized needle penetration test. After design, the setup was fabricated by means of 3D printing and mounted onto an universal testing machine. For testing the setup, a 3D printable polymer with low Shore A hardness and porcine aorta were used. The evaluation was made by comparing the curves of the penetration force to the standardized test considering the expected differences.

Results

3D printing proved to be suitable for manufacturing the test setup, which finally was able to mimic wall tension as if under blood pressure and penetration angle. The force displacement diagrams showed the expected curves and allowed a conclusion to the mechanical properties of the materials. Although the materials forces deviated between the porcine aorta and the Agilus30 polymer, the graphs showed similar but still characteristic curves.

Conclusions

The test bench provided the expected results and was able to show the differences between the two materials. To improve the setup, limitations has been discussed and changes can be implemented without complications.

Supplementary Information

The online version contains supplementary material available at 10.1186/s41205-021-00110-y.

Ring orthosis design and production by rapid prototyping approach

STUDY DESIGN

In this study, ring orthosis design and manufacturing was performed by using rapid prototyping technology.

INTRODUCTION

Swan neck and boutonniere deformities may occur because of various reasons such as tendon injuries, sharp object injuries, or rheumatic diseases. Although the ring orthoses are the most commonly used conservative treatment method for swan neck and buttonhole deformities, they cannot be widely used because they are both difficult to produce and esthetically unsatisfied with the patients.

PURPOSE OF THE STUDY

In this study, it was aimed to manufacture with an orthosis design that is fully compatible, more esthetic, faster, and easily produced.

METHODS

3D printing technologies are used in design and manufacturing. The 3D scanner is used in the measurement process, and the 3D printer is used in the manufacturing process.

RESULTS

As a result of the study, a more esthetically pleasing and comfortable orthosis was made faster.

DISCUSSION AND CONCLUSIONS

As a result of the study, the thickness of the material should not be less than 5 mm.

Case study into the successful emergency production and certification of a filtering facepiece respirator for Belgian hospitals during the COVID-19 pandemic

The SARS-CoV-2 pandemic presented European hospitals with chronic shortages of personal protective equipment (PPE) such as surgical masks and respirator masks. Demand outstripped the production capacity of certified European manufacturers of these devices. Hospitals perceived emergency local manufacturing of PPE as an approach to reduce dependence on foreign supply. The fact of a pandemic does not circumvent the hospital's responsibility to provide appropriate protective equipment to their staff, so the emergency production needed to result in devices that were certified by testing agencies. This paper is a case study of the emergency manufacturing of respirator masks during the first month of the first wave of SARS-CoV-2 pandemic and is separated into two distinct phases. Phase A describes the three-panel folding facepiece respirator design, material sourcing, performance testing, and an analysis of the folding facepiece respirator assembly process. Phase B describes the redevelopment of individual steps in the assembly process.

Homemade 3D mirror imaging models utility for surgical treatment of complex fractures of scapula

The treatment of complex articular scapular fractures requires obtaining an anatomic reduction. The experience of the surgeon and the surgical skills needed are still the most important aspect in this surgical field. 3D printed models at a 1:1 scale provides tactile and visual experience. We used a specular healthy scapula (reverse engineering) as a reliable template for preoperative planning. We pre-contour plates directly over a printed mold, for direct application, without further corrections during the surgical procedure. This reduces improvisation during surgery, the risks of complications and the total costs while improving the accuracy of the anatomical restoration of the native glenopolar angle derived from the indirect reduction of the fracture. Until recently, the use of RP (rapid prototyping) models for managing complex fractures required contracting the services provided by external companies, with the constraints posed on cost and time. We made the whole process ourselves in a DIY mode: from the post-processed radiological images to the 3D model printing, pre contoured plates and surgical simulation.

3D Printing for Cardiovascular Applications: From End-to-End Processes to Emerging Developments

3D printing as a means of fabrication has seen increasing applications in medicine in the last decade, becoming invaluable for cardiovascular applications. This rapidly developing technology has had a significant impact on cardiovascular research, its clinical translation and education. It has expanded our understanding of the cardiovascular system resulting in better devices, tools and consequently improved patient outcomes. This review discusses the latest developments and future directions of generating medical replicas ('phantoms') for use in the cardiovascular field, detailing the end-to-end process from medical imaging to capture structures of interest, to production and use of 3D printed models. We provide comparisons of available imaging modalities and overview of segmentation and post-processing techniques to process images for printing, detailed exploration of latest 3D printing methods and materials, and a comprehensive, up-to-date review of milestone applications and their impact within the cardiovascular domain across research, clinical use and education. We then provide an in-depth exploration of future technologies and innovations around these methods, capturing opportunities and emerging directions across increasingly realistic representations, bioprinting and tissue engineering, and complementary virtual and mixed reality solutions. The next generation of 3D printing techniques allow patient-specific models that are increasingly realistic, replicating properties, anatomy and function.

Dosimetric evaluation of a patient-specific 3D-printed oral positioning stent for head-and-neck radiotherapy

As head-and-neck radiotherapy treatments become more complex and sophisticated, and the need to control and stabilise the positioning of intra-oral anatomy becomes more important, leading the increasing use of oral positioning stents during head-and-neck radiotherapy simulation and delivery. As an alternative to the established practice of creating oral positioning stents using wax, this study investigated the use of a 3D printing technique. An Ender 5 3D printer (Creality 3D, Shenzhen, China) was used, with PLA+ "food-safe" polylactic acid filament (3D Fillies, Dandenong South, Australia), to produce a low-density 3D printed duplicate of a conventional wax stent. The physical and dosimetric effects of the two stents were evaluated using radiochromic film in a solid head phantom that was modified to include flexible parts. The Varian Eclipse treatment planning system (Varian Medical Systems, Palo Alto, USA) was used to calculate the dose from two different head-and-neck treatment plans for the phantom with each of the two stents. Examination of the resulting four dose distributions showed that both stents effectively pushed sensitive oral tissues away from the treatment targets, even though most of the phantom was solid. Film measurements confirmed the accuracy of the dose calculations from the treatment planning system, despite the steep density gradients in the treated volume, and demonstrated that the 3D print could be a suitable replacement for the wax stent. This study demonstrated a useful method for dosimetrically testing novel oral positioning stents. We recommend the development of flexible phantoms for future studies.

Accuracy of 3D printing compared with milling - A multi-center analysis of try-in dentures

OBJECTIVES

In recent years, computer-aided design/computer-aided manufacturing (CAD/CAM) has been used to produce removable complete dentures. Most workflows include fabrication of milled or 3D-printed try-in prostheses. 3D-printing accuracy is affected by laboratory-specific and operator-dependent factors. This international five-center study sought to compare the accuracy of 3D-printed and milled try-in dentures.

METHODS

The construction file of a maxillary removable complete denture was selected as a reference. Eight try-in dentures were 3D printed at each of the five centers. Each center used their own printer (Objet260 Connex, Stratasys; MAX, Asiga; Anycubic Photon, Anycubic 3D; PRO2, Asiga and cara Print 4.0, Kulzer) along with their own material, printing settings, post-processing and light-curing parameters. At center 2, eight try-in dentures were milled to serve as a benchmark (PrograMill PM7, Ivoclar Vivadent). Dentures were scanned and aligned to the reference file using best-fit algorithms. Geometric accuracy was analyzed using the root mean square value (trueness) and standard deviation (precision) of the distributed absolute mesh deviations. Mean values of the five sets of printed dentures and the single set of milled dentures were compared.

RESULTS

Milled dentures showed a mean trueness of 65 ± 6 μm and a mean precision of 48 ± 5 μm. Thus, they were significantly more accurate than the 3D-printed dentures in four out of five centers. In mean absolute numbers, 3D printing was less true than milling by 17-89 μm and less precise by 8-66 μm.

CONCLUSIONS

Although milling remains the benchmark technique for accuracy, differences between milled and 3D-printed dentures were non-significant for one printing center. Furthermore, the overall performance of 3D printing at all centers was within a clinically acceptable range for try-in prostheses.

CLINICAL SIGNIFICANCE

The accuracy of 3D printing varies widely between and within laboratories but nonetheless lies within the range of accuracy of conventional manufacturing methods.

3D printing in neurosurgery education: a review

OBJECTIVES

The objectives of this manuscript were to review the literature concerning 3D printing of brain and cranial vault pathology and use these data to define the gaps in global utilization of 3D printing technology for neurosurgical education.

METHODS

Using specified criteria, literature searching was conducted to identify publications describing engineered neurosurgical simulators. Included in the study were manuscripts highlighting designs validated for neurosurgical skill transfer. Purely anatomical designs, lacking aspects of surgical simulation, were excluded. Eligible manuscripts were analyzed. Data on the types of simulators, representing the various modelled neurosurgical pathologies, were recorded. Authors' countries of affiliation were also recorded.

RESULTS

A total of thirty-six articles, representing ten countries in five continents were identified. Geographically, Africa as a continent was not represented in any of the publications. The simulation-modelling encompassed a variety of neurosurgical subspecialties including: vascular, skull base, ventriculoscopy / ventriculostomy, craniosynostosis, skull lesions / skull defects, intrinsic brain tumor and other. Finally, the vascular and skull base categories together accounted for over half (52.8 %) of the 3D printed simulated neurosurgical pathology.

CONCLUSIONS

Despite the growing body of literature supporting 3D printing in neurosurgical education, its full potential has not been maximized. Unexplored areas of 3D printing for neurosurgical simulation include models simulating the resection of intrinsic brain tumors or of epilepsy surgery lesions, as these require complex models to accurately simulate fine dissection techniques. 3D printed surgical phantoms offer an avenue for the advancement of global-surgery education initiatives.

[Comparative study between 3D guide plate assisted and free-hand insertion of anterior cervical transpedicular screw]

OBJECTIVE

To compare accuracy of anterior cervical pedicle screws between assist of rapid prototyping 3D guide plate and free-hand insertion, and evaluate the safety of two methods.

METHODS

Eight adult cervical cadaver specimens after formaldehyde immersion, including 4 males and 4 females, aged 32 to 65(40.3±5.6) years old. After X-ray examination to exclude bone damage and deformity, 4 of them (3D guide plate group) randomly selected were for CT scan to obtain DICOM format data, and the data was imported into Mimics software for model, designed the ideal entry point and nail path for anterior cervicaltranspedicular screw (ATPS). After obtaining the personalized guide plate of the nail channel, it was exported as STL data, and the individual guide plate was printed by rapid prototyping and 3D printing technology. In turn, with the assistance of 3D guide plates, one-to-one personalized ATPS screws were placed on the four lower cervical cadaver specimens. Another 4 (free-hand group) lower cervical cadaver specimens were implanted with ATPS screws using free-hand technique. All specimens were performed CT thin-layer scanning and three-dimensional reconstruction after operation. The Tomasino method was used to evaluate the safety of the screws on the CT cross-sectional and sagittal images, to determine whether there was a cortical puncture of the lower and inner edges of the pedicle. According to the CT rating results, gradeⅠandⅡwere safe, and grade Ⅲ- Ⅴ were dangerous.And the accuracy of screws was recorded and analyzed between two groups.

RESULTS

Two screws were inserted in each segment from C₃ to C₇ in 8 adult cadavers. A total of 80 screws were inserted, 40 in the 3D guide plate group, and 40 in the free-hand group. The Tomasino screw rating method was used to evaluate the safety of screw, 21 screws were gradeⅠ, 14 screws were gradeⅡ, 3 screws were grade Ⅲ, 1 screw was grade Ⅳ, 2 screws were grade Ⅴ in 3D guide plate group, while 14 screws were gradeⅠ, 8 screws were gradeⅡ, 8 screws were grade Ⅲ, 6 screws were grade Ⅳ, 2 screws were grade Ⅴ in free-hand group. The safety rate of 3D guide plate group was 87.5%, and 55.0% of the free hand group (χ²=8.7, P=0.003).

CONCLUSION

The 3D printing rapid prototyping guide plate assisted insertion of the anterior cervical pedicle screw can significantly improve the accuracy and safety, and provide a theoretical basis for further clinical application.

Elution behavior of a 3D-printed, milled and conventional resin-based occlusal splint material

OBJECTIVE

The elution of unpolymerized (co-)monomers and additives from methacrylic resin-based materials like polymethyl methacrylate (PMMA) can cause adverse side effects, such as mutagenicity, teratogenicity, genotoxicity, cytotoxicity and estrogenic activity. The aim of this study was to quantify the release and the cytotoxicity of residual (co-)monomers and additives from PMMA-based splint materials under consideration of real splint sizes. Three different materials used for additive (3D printing), subtractive (milling) and conventional (powder and liquid) manufacturing were examined.

METHODS

The splint materials SHERAprint-ortho plus (additive), SHERAeco-disc PM20 (subtractive) and SHERAORTHOMER (conventional) were analysed. 16 (n = 4) sample discs of each material (6 mm diameter and 2 mm height) were polished on the circular and one cross-section area and then eluted in both distilled water and methanol. The discs were incubated at 37 °C for 24 h or 72 h and subsequently analysed by gas chromatography/mass spectrometry (GC/MS) for specifying and quantifying released compounds. XTT-based cell viability assays with human gingival fibroblasts (HGFs) were performed for Tetrahydrofurfuryl methacrylate (THFMA), 1,4-Butylene glycol dimethacrylate (BDDMA) and Tripropylenglycol diacrylate (TPGDA). In order to project the disc size to actual splint sizes in a worst-case scenario, lower and upper jaw occlusal splints were designed and volumes and surfaces were measured.

RESULTS

For SHERAeco-disc PM20 and for SHERAORTHOMER no elution was determined in water. SHERAprint-ortho plus eluted the highest THFMA concentration of 7.47 μmol/l ±2,77 μmol/l after 72 h in water. Six (co-)monomers and five additives were detected in the methanol eluates of all three materials tested. The XTT-based cell viability assays resulted in a EC₅₀ of 3006 ± 408 μmol/l for THFMA, 2569.5 ± 308 μmol/l for BDDMA and 596.7 ± 88 μmol/l for TPGDA.

SIGNIFICANCE

With the solvent methanol, released components from the investigated splint materials exceeded cytotoxic concentrations in HGFs calculated for a worst-case scenario in splint size. In the water eluates only the methacrylate THFMA could be determined from SHERAprint-ortho plus in concentrations below cytotoxic levels in HGFs.

Novel additive manufacturing applications for communicable disease prevention and control: focus on recent COVID-19 pandemic

COVID-19 disease caused by the SARS-CoV-2 virus has had serious adverse effects globally in 2020 which are foreseen to extend in 2021, as well. The most important of these effects was exceeding the capacity of the healthcare infrastructures, and the related inability to meet the need for various medical equipment especially within the first months of the crisis following the emergence and rapid spreading of the virus. Urgent global demand for the previously unavailable personal protective equipment, sterile disposable medical supplies as well as the active molecules including vaccines and drugs fueled the need for the coordinated efforts of the scientific community. Amid all this confusion, the rapid prototyping technology, 3D printing, has demonstrated its competitive advantage by repositioning its capabilities to respond to the urgent need. Individual and corporate, amateur and professional all makers around the world with 3D printing capacity became united in effort to fill the gap in the supply chain until mass production is available especially for personal protective equipment and other medical supplies. Due to the unexpected, ever-changing nature of the COVID-19 pandemic-like all other potential communicable diseases-the need for rapid design and 3D production of parts and pieces as well as sterile disposable medical equipment and consumables is likely to continue to keep its importance in the upcoming years. This review article summarizes how additive manufacturing technology can contribute to such cases with special focus on the recent COVID-19 pandemic.

Rapid and simple pressure-sensitive adhesive microdevice fabrication for sequence-specific capture and fluorescence detection of sepsis-related bacterial plasmid gene sequences

Microbial resistance to currently available antibiotics poses a great threat in the global fight against infections. An important step in determining bacterial antibiotic resistance can be selective DNA sequence capture and fluorescence labeling. In this paper, we demonstrate the fabrication of simple, robust, inexpensive microfluidic devices for DNA capture and fluorescence detection of a model antibiotic resistance gene sequence. We laser micromachined polymethyl methacrylate microchannels and enclosed them using pressure-sensitive adhesive tapes. We then formed porous polymer monoliths with DNA capture probes in these microchannels and used them for sequence-specific capture, fluorescent labeling, and laser-induced fluorescence detection of picomolar (pM) concentrations of synthetic and plasmid antibiotic resistance gene targets. The relative fluorescence for the elution peaks increased with loaded target DNA concentration. We observed higher fluorescence signal and percent recovery for synthetic target DNA compared to plasmid DNA at the same loaded target concentration. A non-target gene was used for control experiments and produced < 3% capture relative to the same concentration of target. The full analysis process including device fabrication was completed in less than 90 min with a limit of detection of 30 pM. The simplicity of device fabrication and good DNA capture selectivity demonstrated herein have potential for application with processes for bacterial plasmid DNA extraction and single-particle counting to facilitate determination of antibiotic susceptibility. Graphical abstract.

Surgical planning using facial fracture 3D models: The role of cyanoacrylate glue and miniplating for anatomical reduction

Background

In comminuted facial fractures, peri-operative use of 3D-printed life size models is increasingly a useful adjunct. It allows for preoperative surgical rehearsal and plate bending, to achieve anatomical reduction with reduced operative time and cost. One problem encountered is difficulty contouring the fixation plate whilst maintaining the relative spatial orientation of comminuted fragments. This paper shares an effective method of overcoming this problem.

Methods

All comminuted facial fracture patients underwent counselling for 3D printing. Pre-printing thresholding and segmentation of each fragment (as directed by the surgeon) were done by the radiologist and the engineering team, using the multi-slice CT Face DICOM data. Life-size 3D-resin models of the fractures were printed. Fast-acting medium consistency cyanoacrylate glue (Zap-A-Gap^Ⓡ) and miniplates were used to assemble the printed model segments in ‘anatomic reduction’. Aerosolized alcohol accelerator facilitated immediate glue curing, providing a stable model. The plates were adapted over this restored neonative 3D construct with bending inserts, sterilized and used intraoperatively. The 3D model was used to guide the operative sequence. Intraoperative CT was used in select cases to confirm anatomic reduction.

Results/Complications

All patients (n = 5) had comminuted fractures in at least one of the bony units (mandible, maxilla or orbits) and one was a pan-facial fracture case. 3D printed models aided fracture reduction and fixation, whilst avoiding the guesswork in ascertaining the contour of the mandibular arch. In addition, the pre-contoured mandible plates restored premorbid occlusion and projection, without the need for long-term archbars in all cases. Operative time was estimated to be reduced by 0.5–1 h. Resident teaching was enhanced by this approach.

Conclusion

The application of medium consistency fast-acting cyanoacrylate glue and miniplates facilitated the creation of the premorbid facial skeletal model and allowed pre-bending of the plates, thus saving operative time and cost.

Laboratory efficiency of additive manufacturing for removable denture frameworks: A literature-based review

The purpose of this literature review was to verify the laboratory efficiency of additive manufacturing (AM) systems for removable partial denture (RPD) frameworks. All available relevant articles in English published from 1990 to 2020 were found by searching online databases and by hand research. A total of 17 articles dealt with the surface roughness, fitness accuracy, and retentive forces of AM frameworks. The surface roughness of AM was inferior to that of casting and milling. Whether conventional cast or AM RPD frameworks had superior fitness accuracy could not be clarified. As compared with casting and AM, milling enabled the fabrication of RPD clasps with comparable or better fitness accuracy. Over time, AM clasps had retentive force values of superior consistency as compared with those of conventional cast clasps. Clasps fabricated by repeated laser sintering and high-speed milling could obtain smoother surfaces and more suitable retention than those of AM clasps.

3D printed complete removable dental prostheses: a narrative review

Background

The purpose of this paper is to review the available literature on three-dimensionally printed complete dentures in terms of novel biomaterials, fabrication techniques and workflow, clinical performance and patient satisfaction.

Methods

The methodology included applying a search strategy, defining inclusion and exclusion criteria, selecting studies and forming tables to summarize the results. Searches of PubMed, Scopus, and Embase databases were performed independently by two reviewers to gather literature published between 2010 and 2020.

Results

A total of 126 titles were obtained from the electronic database, and the application of exclusion criteria resulted in the identification of 21 articles pertaining to printed technology for complete dentures. Current innovations and developments in digital dentistry have successfully led to the fabrication of removable dental prostheses using CAD/CAM technologies. Milled dentures have been studied more than 3D printed ones in the currently available literature. The limited number of clinical studies, mainly case reports, suggest current indications of 3D printing in denture fabrication process to be custom tray, record bases, trial, interim or immediate dentures but not definitive prostheses fabrication. Limitations include poor esthetics and retention, inability to balance occlusion and low printer resolution.

Conclusions

Initial studies on digital dentures have shown promising short-term clinical performance, positive patient-related results and reasonable cost-effectiveness. 3D printing has potential to modernize and streamline the denture fabrication techniques, materials and workflows. However, more research is required on the existing and developing materials and printers to allow for advancement and increase its application in removable prosthodontics.

Accuracy evaluation of complete-arch models manufactured by three different 3D printing technologies: a three-dimensional analysis

Purpose This study aimed to evaluate the trueness and precision of complete-arch models printed with three-dimensional printers via three different printing technologies.Methods An arch-shaped master model was designed using software (RapidForm XOR2, 3D Systems Inc., USA), and the digital master model was printed 10 times with three-dimensional printers using stereolithography (SLA), direct light processing (DLP), and Polyjet technology (n = 30). The printed models were then scanned with an industrial scanner to create the respective digital models. All digital models were compared with the master model, and an evaluation of the trueness was performed by model superimposition with Geomagic Control software (3D Systems, Rock Hill, SC, USA). Precision was determined for each case by superimposing some combination of the 10 datasets in each group.Results The trueness of the printed models was 46.2 µm for the DLP printer, 51.6 µm for the SLA printer, and 58.6 µm for the Polyjet printer. The DLP models were significantly better than the Polyjet models (p = .005). However, the Polyjet models (30.4 µm) were more precise than the SLA (37.6 µm) and DLP (43.6 µm) models (p < .001, p = .016). Furthermore, the SLA (11.8 µm) was the most accurate printer in the Z-direction (p = .016, p = .002).Conclusions The 3D printing technologies showed significant differences in the precision and trueness of complete-arch measurements. Although DLP was more accurate other tested 3D printers, the accuracy of all 3D printed models was within clinical tolerance, and they were clinically acceptable and could be used for the production of fixed restorations.