3D Printed Maxillofacial Prostheses with Digital Scanning
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Solution Overview
Problem
Traditional methods for forming maxillofacial prostheses, radiation boluses, and burn masks are time-consuming and prone to soft tissue distortion, requiring multiple patient visits and lengthy processes.
Innovation Solution
The method involves electronically designing a digital model using topographic scans, CT, or MRI data, and forming the prosthesis using rapid prototyping techniques such as 3D printing, stereolithography, or selective laser sintering, with a polymer scaffolding and silicone coating to mimic the patient's anatomy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional impression and molding methods are used, then the prosthesis can be formed, but the process takes a relatively long amount of time and requires multiple office visits
Solution Approach 1:
The patent performs preliminary scanning and digital modeling of the patient's anatomy before the prosthesis fabrication process begins. The topographic scan and digital twin creation are completed in advance, allowing the physical prosthesis manufacturing to start immediately without requiring multiple patient visits for impressions and adjustments.
Solution Approach 2:
The patent creates a digital copy (digital twin) of the patient's anatomy through topographic scanning. This digital model serves as a precise replica that can be manipulated, analyzed, and used for prosthesis design without requiring physical impressions or multiple patient visits, significantly reducing time loss.
2Manufacturing precision
If traditional impression methods are used, then the prosthesis can be formed, but soft tissue distortion occurs during impression taking
Solution Approach 1:
The patent replaces the mechanical impression-taking process (which causes soft tissue distortion) with a non-contact optical scanning system. The topographic scanner uses light to capture surface geometry, eliminating the need for physical impression materials that distort soft tissue while maintaining or improving anatomical accuracy.
Solution Approach 2:
The patent creates a digital copy of the patient's surface anatomy through non-contact scanning, preserving the true anatomical form without the distortion caused by traditional impression materials. The digital model accurately represents the soft tissue surface geometry without deforming it.
3Adaptability or versatility
If a single-material prosthesis is used, then the manufacturing process is simpler, but the prosthesis cannot provide multiple zones of varying flexibility
Solution Approach 1:
The patent applies local quality by creating zones within the prosthesis that have different material properties, specifically different flexibility levels. The digital model allows precise definition of these zones to match the functional requirements of different anatomical regions, with each zone having optimized material characteristics for its specific location.
Solution Approach 2:
The patent uses composite materials with different flexibility characteristics in different zones of the prosthesis. By combining materials with varying physical properties in a single multi-material print job, the prosthesis achieves both adaptability (multiple flexibility zones) and functional complexity without requiring assembly of separate components.
4Productivity
If rapid prototyping is used, then the prosthesis formation time is reduced, but the manufacturing process requires new technologies and equipment
Solution Approach 1:
The patent uses digital copying to create an accurate digital twin of the patient's anatomy, which serves as a blueprint for the rapid prototyping process. This digital model can be directly imported into rapid prototyping software, eliminating the need for physical patterns or molds and streamlining the transition from scanning to manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the time required for prosthesis formation, minimizes soft tissue distortion, and allows for more accurate and flexible prosthetics with multiple zones of varying flexibility, improving patient outcomes.
Implementation Method 1
forming at least a portion of the prosthesis, radiation bolus, pre-surgical model, or burn mask using rapid prototyping methods based on the digital model of the prosthesis, radiation bolus, pre-surgical model, or burn mask. The forming may include printing at least a portion of the prosthesis using a rapid prototyping device based on the digital model of the prosthesis.
Data Source
AI summary
A prosthesis, radiation bolus, pre-surgical model, or burn mask formed using a rapid prototyping device, such as a three-dimensional printer. In some exemplary aspects, the prosthesis includes a scaffolding and a coating at least partially covering the scaffolding. Methods and systems for forming the prosthesis, radiation bolus, pre-surgical model, or burn mask are also provided.