Reconstruction of customized zygoma implant and stock orbital floor mesh plate by 3D printing

Sh. Sharma, V. Rattan, H. Kumar Banga, P. Kalra, V. Kumar, J. S.Randhawa

Abstract: To design and develop a cost-effective technique of using patient-specific implants for the reconstruction of large maxillofacial defects that require multiple fragments of the region involving zygoma and orbital floor. The patient suffering from ossifying fibroma entailing right maxilla, zygoma and orbit floor was planned for reconstruction using patient specific implant (PSI). Requiring multi-fragmental reconstruction of the large defect, a two-piece implant was designed using CAD (Computer aided design) software for zygoma and orbital floor. Consequentially, due to its large size, weight and less bony support it was impossible to place the implants. Thus, as an alternative, one PSI was designed for zygoma and combined with a commercially available titanium mesh for orbital floor. The mesh was fixed with zygoma implant by Titanium (Ti) screws at the cheek bone site. Both were checked for rigidity on 3D printed prototypes before fabricating the PSI in Titanium (Ti6Al4V) using direct metal laser sintering (DMLS) 3D printing technology. Using commercially available orbital mesh with a single-piece zygoma PSI for large orbito zygomatic defects replaces the requirement of two-piece implant. It not only reduces the size and weight but also improves intraoperative placement with reduction of cost of the implants. Hence, with the effective use of CAD and 3D printing, the cost of implant is reduced by 66.6% thereby, benefiting the patient economically.


Series on Biomechanics, Vol.35 No.4 (2021), 62-70

Keywords: 3D printing; cost effective; customized orbito zygomatic; multi fragmental; post traumatic

Date published: 2021-12-29