3D printing to rebuild patient's face

3D printing to rebuild patient's face

Surgeons in Swansea are using 3D printing technology to rebuild a patient's face which was crushed in a motorbike accident.

It works by using images from a CT scan to design implants that are created in titanium by a 3D printer.

The groundbreaking work is being led by Morriston Hospital consultant maxillofacial surgeon Adrian Sugar.

It is being featured in an exhibition at the Science Museum in London before the operation itself is carried out.

There have been cases using custom-made titanium implants to correct congenital conditions, those which arise at birth or shortly after.

However, this is thought to be one of the first such reconstructions following an injury.

Abertawe Bro Morgannwg University Health Board's maxillofacial laboratory services manager and reconstructive scientist Peter Evans said: "The patient suffered trauma and had multiple injuries across his body, including some quite severe facial injuries.

"He underwent emergency surgery at the time and we are now at the stage where we can do a proper reconstruction of his face."

The project is the work of the Centre of Applied Reconstructive Technologies in Surgery (Cartis).

The centre was established in 2006 as a partnership between Morriston Hospital's maxillofacial unit and Product Design and Research (PDR) based at Cardiff Metropolitan University.

Cartis aims to make Wales a world leader in the research, development and application of advanced medical technologies in surgery.

Mr Sugar and Mr Evans worked with PDR's Sean Peel and Ffion O'Malley to plan the complex surgery, which will involve repositioning the patient's facial bones.

They worked from a CT scan that allowed them to create a mirror image of the unaffected side of the patient's face.

From this they designed guides to cut and position the bones with pinpoint accuracy, as well as implants tailor-made for the patient.

The guides and implants are being produced from medical-grade titanium in Belgium.

Mr Evans added: "We have done everything up the point of surgery. The concept of the operation has been virtually designed and we hope to do the work very soon.

"The patient's facial symmetry will be restored so he should be back to normal as far as his facial looks are concerned."