Development of a 3-dimensionally printed model of sinonasal anatomy

Background Recent studies of 3-dimensional (3D) printing in otolaryngology were focused on sinonasal structures and the temporal bone. Patient-specific anatomical models could be useful for preoperative planning and resident training. The aims of our study were to create and validate a 3D-printed model of bony paranasal sinus anatomy.

Methods Open source software (ITK-Snap) was used to segment bony sinonasal structures of a high-resolution CT scan (1mm slices, DICOM format). After exporting data as Standart Tessellation Laguage (STL) file a commercially available printer software (XYZware) converted the segmentation into printable slices. The model was fabricated with a stereolithographic 3D-printer (Nobel 1.0, XYZ printing Inc., Taiwan) using photopolymer resin. Image-guided navigation (Fiagon AG, Hennigsdorf, Germany) was used to validate anatomical accuracy.

Results Segmentation of CT scan images and conversion into a 3D-printable file required four hours. After a printing time of 24 hours postprocessing time was three hours. During postprocessing the model was rinsed with isopropyl alcohol followed by UV-hardening and removing of support material. The material cost of the model was 34,-€. Image-guided navigation confirmed tolerance of surgical landmarks within ±1mm.

Conclusions High-resolution models of sinonasal anatomy can be produced with a stereolithographic 3D-printer using photopolymer resin. This technology could be useful for surgical training and patient-specific preoperative planning.

Publication History

Article published online:
10 June 2020