The most common three-dimensional (3D) printing method is material extrusion, where a pre-made filament is deposited layer-by-layer. In recent years, low-cost polycaprolactone (PCL) material has increasingly been used in 3D printing, exhibiting a sufficiently high quality for consideration in cranio-maxillofacial reconstructions. To increase osteoconductivity, prefabricated filaments for bone repair based on PCL can be supplemented with hydroxyapatite (HA). However, few reports on PCL/HA composite filaments for material extrusion applications have been documented. In this study, solvent-free fabrication for PCL/HA composite filaments (HA 0%, 5%, 10%, 15%, 20%, and 25% weight/weight PCL) was addressed, and parameters for scaffold fabrication in a desktop 3D printer were confirmed. Filaments and scaffold fabrication temperatures rose with increased HA content. The pore size and porosity of the six groups’ scaffolds were similar to each other, and all had highly interconnected structures. Six groups’ scaffolds were evaluated by measuring the compressive strength, elastic modulus, water contact angle, and morphology. A higher amount of HA increased surface roughness and hydrophilicity compared to PCL scaffolds. The increase in HA content improved the compressive strength and elastic modulus. The obtained data provide the basis for the biological evaluation and future clinical applications of PCL/HA material.

Pure orbital blowout fractures occur within the confines of the internal orbital wall. Restoration of orbital form and volume is paramount to prevent functional and esthetic impairment. The anatomical peculiarity of the orbit has encouraged surgeons to develop implants with customized features to restore its architecture. This has resulted in worldwide clinical demand for patient-specific implants (PSIs) designed to fit precisely in the patient’s unique anatomy. Material extrusion or Fused filament fabrication (FFF) three-dimensional (3D) printing technology has enabled the fabrication of implant-grade polymers such as Polyetheretherketone (PEEK), paving the way for a more sophisticated generation of biomaterials. This study evaluates the FFF 3D printed PEEK orbital mesh customized implants with a metric considering the relevant design, biomechanical, and morphological parameters. The performance of the implants is studied as a function of varying thicknesses and porous design constructs through a finite element (FE) based computational model and a decision matrix based statistical approach. The maximum stress values achieved in our results predict the high durability of the implants, and the maximum deformation values were under one-tenth of a millimeter (mm) domain in all the implant profile configurations. The circular patterned implant (0.9 mm) had the best performance score. The study demonstrates that compounding multi-design computational analysis with 3D printing can be beneficial for the optimal restoration of the orbital floor.

Cranioplasty with freehand-molded polymethylmethacrylate implants is based on decades of experience and is still frequently used in clinical practice. However, data confirming the fracture toughness and standard biomechanical tests are rare. This study aimed to determine the amount of force that could be applied to virtually planned, template-molded, patient-specific implants (n = 10) with an implant thickness of 3 mm, used in the treatment of a temporoparietal skull defect (91.87 cm²), until the implant cracks and finally breaks. Furthermore, the influence of the weight and porosity of the implant on its force resistance was investigated. The primary outcome showed that a high force was required to break the implant (mean and standard deviation 1484.6 ± 167.7 N), and this was very strongly correlated with implant weight (Pearson’s correlation coefficient 0.97; p < 0.001). Secondary outcomes were force application at the implant’s first, second, and third crack. Only a moderate correlation could be found between fracture force and the volume of porosities (Pearson’s correlation coefficient 0.59; p = 0.073). The present study demonstrates that an implant thickness of 3 mm for a temporoparietal skull defect can withstand sufficient force to protect the brain. Greater implant weight and, thus, higher material content increases thickness, resulting in more resistance. Porosities that occur during the described workflow do not seem to reduce resistance. Therefore, precise knowledge of the fracture force of polymethylmethacrylate cranial implants provides insight into brain injury prevention and serves as a reference for the virtual design process.

Purpose: The use of computer-assisted virtual surgical planning (VSP) for craniosynostosis surgery is gaining increasing implementation in the clinics. However, accurately transferring the preoperative planning data to the operating room remains challenging. We introduced and investigated a fully digital workflow to perform fronto-orbital advancement (FOA) surgery using 3D-printed patient-specific implants (PSIs) and cold-ablation robot-guided laser osteotomy. This novel approach eliminates the need for traditional surgical templates while enhancing precision and customization, offering a more streamlined and efficient surgical process. Methods: Computed tomography data of a patient with craniosynostosis were used to digitally reconstruct the skull and to perform VSP of the FOA. In total, six PSIs per skull were 3D-printed with a medical-grade bioresorbable composite using the Arburg Plastic Freeforming technology. The planned osteotomy paths and the screw holes, including their positions and axis angles, were digitally transferred to the cold-ablation robot-guided osteotome interface. The osteotomies were performed on 3D-printed patient skull models. The implants, osteotomy and final FOA results were scanned and compared to the VSP data. Results: The osteotomy deviations for the skulls indicated an overall maximum distance of 1.7 mm, a median deviation of 0.44 mm, and a maximum root mean square (RMS) error of 0.67 mm. The deviation of the point-to-point surface comparison of the FOA with the VSP data resulted in a median accuracy of 1.27 mm. Accessing the orbital cavity with the laser remained challenging. Conclusion: This in vitro study showcases a novel FOA technique by effectively combining robot-guided laser osteotomy with 3D-printed patient-specific implants, eliminating the need for surgical templates and achieving high accuracy in bone cutting and positioning. The workflow holds promise for reducing preoperative planning time and increasing surgical efficiency. Further studies on bone tissue are required to validate the safety and effectiveness of this approach, especially in addressing the challenges of pediatric craniofacial surgery.

Advancements in personalized medicine, threedimensional (3D) printing, miniaturization, and robot-assisted surgery are driving innovation in tissue engineering. A novel approach, known as in situ printing, focuses on the direct deposition of materials at the surgical site. Using the in situ printing approach, bone and/or cartilage defects can be addressed with high precision. Furthermore, highly customized 3D printed tissue constructs or implants can be deposited directly inside the body. Currently, most applications of in situ printing are limited to areas near the skin or open surgeries. Even though a minimally invasive approach would bring clinical benefits, only a few research groups have focused on this field. In this scoping review, we provide an overview of the current state of in situ minimally invasive 3D printing technology for bone and cartilage regeneration and discuss its advantages and current challenges.