In the relevant global context, although virtual reality, augmented reality, and mixed reality have been emerging methodologies for several years, only now have technological and scientific advances made them suitable for revolutionizing clinical care and medical settings through the provision of advanced features and improved healthcare services. Over the past fifteen years, tools and applications using augmented reality (AR) have been designed and tested in the context of various surgical and medical disciplines, including maxillofacial surgery. The purpose of this paper is to show how a marker-less AR guidance system using the Microsoft^® HoloLens 2 can be applied in mandible and maxillary demolition surgery to guide maxillary osteotomies. We describe three mandibular and maxillary oncologic resections performed during 2021 using AR support. In these three patients, we applied a marker-less tracking method based on recognition of the patient’s facial profile. The surgeon, using HoloLens 2 smart glasses, could see the virtual surgical planning superimposed on the patient’s anatomy. We showed that performing osteotomies under AR guidance is feasible and viable, as demonstrated by comparison with osteotomies performed using CAD-CAM cutting guides. This technology has advantages and disadvantages. However, further research is needed to improve the stability and robustness of the marker-less tracking method applied to patient face recognition.

Although the fibula free flap represents the gold standard for mandibular reconstructions, when implanted as a single barrel, this flap does not have the cross-sectional requisites to restore the native mandibular height, which is in turn required for the implant-supported dental rehabilitation of the patient. Our team has developed a design workflow that already considers the predicted dental rehabilitation, positioning the fibular free flap in the correct craniocaudal position to restore the native alveolar crest. The remaining height gap along the inferior mandibular margin is then filled by a patient-specific implant. The aim of this study is to evaluate the accuracy in transferring the planned mandibular anatomy resulting from said workflow on 10 patients by means of a new rigid body analysis method, derived from the evaluation of orthognathic surgery procedures. The analysis method has proved to be reliable and reproducible, and the results obtained show that the procedure already has satisfactory accuracy (4.6° mean total angular discrepancy, 2.7 mm total translational discrepancy, 1.04 mm mean neo-alveolar crest surface deviation), while also pointing out possible improvements to the virtual planning workflow.

Osteonecrosis of the jaw (ONJ) is a disease that affects the jaw. It is mainly related to radiation or bisphosphonates therapy, and the symptoms and signs consist of pain, bone exposure, inflammation of the surrounding soft tissue swelling, and secondary infection or drainage. In the case of advanced disease of the mandibular area, the treatment of choice is mandibular resection and reconstruction. In the present study, we report a case series of patients affected by ONJ and treated with a customised bridging mandibular prosthesis-only technique. From 2016 to 2018, we treated five consecutive patients affected by ONJ: three patients were affected by biphosphonate-related osteonecrosis of the mandible (BRONJ) and two were affected by osteoradionecrosis of the mandible (ORNJ). Three patients needed a soft tissue free flap to permit optimal wound closure, intra- and/or extraorally. All reconstructive procedures were carried out successfully, with no major or minor microvascular complication. The average postoperative follow-up was 24.8 (range 10–41) months. Considering that microvascular bone transfer is a high-risk procedure in BRONJ patients, we can conclude that the positioning of a customised bridging mandibular prosthesis (CBMP), whether or not associated with a microvascular soft tissue transfer, is a safe technique in terms of surgical outcome and feasibility.

Preclinical assessment of patient-specific mandibular reconstruction plates relies on bench testing and computational modeling, yet existing setups are typically designed on practical grounds without a structured method to ensure their mechanical relevance to the intended clinical context of use (COU). This study proposes and demonstrates a methodology for constructing and assessing a validation domain with experimental and computational components for patient-specific fibula free flap mandibular reconstruction. A clinical reference finite element model (M-COU) representing the reconstructed mandible under physiological clenching conditions was used as an active design tool to derive the validation setup. Parameters were identified through analytical calibration of M-COU reaction forces and refined via a design-of-experiments procedure. The resulting setup was implemented as two coordinated components: a physical validation platform (R-VAL) enabling bench testing of the actual reconstruction plate, and a validation computational model (M-VAL) reproducing the same setting numerically. The resulting setup preserved the dominant mechanical features of the clinical scenario. In consistency analysis against M-COU, M-VAL achieved R² = 0.75, substantially exceeding literature-based benchmark configurations (R² = 0.27 and 0.40), and was the only configuration to preserve the clinically relevant stress distribution at the mandibular angle. Comparison between M-VAL and R-VAL showed close agreement in initial structural stiffness (0.6% difference) and local strain distribution (R² = 0.93; RMSE = 10.9%). The proposed methodology provides a transferable framework for constructing validation domains that are simultaneously experimentally feasible, mechanically interpretable, and grounded in a defined clinical COU.