Guidelines for Design and Additive Manufacturing Specify the Use of Surgical Templates with Improved Accuracy Using the Masked Stereolithography Technique in the Zygomatic Bone Region
The zygomatic bone area experiences frequent mechanical damage in the middle craniofacial region, including the orbital floor. The orbital floor bone is very thin, ranging from 0.74 mm to 1.5 mm. Enhancing digitization, reconstruction, and CAD modeling procedures is essential to improving the visual...
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| Main Authors: | , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-03-01
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| Series: | Designs |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2411-9660/9/2/33 |
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| Summary: | The zygomatic bone area experiences frequent mechanical damage in the middle craniofacial region, including the orbital floor. The orbital floor bone is very thin, ranging from 0.74 mm to 1.5 mm. Enhancing digitization, reconstruction, and CAD modeling procedures is essential to improving the visualization of this structure. Achieving a homogeneous surface with high manufacturing accuracy is crucial for developing precise surgical models and tools for creating titanium mesh implants to reconstruct the orbital floor geometry. This article improved the accuracy of reconstruction and CAD modeling using the example of the development of a prototype implant to replace the zygomatic bone and a tool to form the geometry of the titanium mesh within the geometry of the orbital floor. The masked stereolithography (mSLA) method was used in the model manufacturing process because it is low-cost and highly accurate. Two manufacturing modes (standard and ultra-light) were tested on an Anycubic Photon M3 Premium 3D printer to determine which mode produced a more accurate representation of the geometry. To verify the geometric accuracy of the manufactured models, a GOM Scan1 structured light scanner was used. In the process of evaluating the accuracy of the model preparation, the maximum deviation, mean deviation, range and standard deviation were determined. The maximum deviations for anatomical structures created using the normal mode ranged from ±0.6 mm to ±0.7 mm. In contrast, models produced with the ultra-light mode showed deviations of ±0.5 mm to ±0.6 mm. Furthermore, the results indicate that the ultra-light mode offers better surface accuracy for die and stamp models. More than 70% of the surface of the models is within the deviation range of ±0.3 mm, which is sufficient for planning surgical procedures. However, the guidelines developed in the presented publication need to optimize the CAD process and select 3D-printing parameters to minimize deviations, especially at the edges of manufactured models. |
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| ISSN: | 2411-9660 |