Output details

Rapid manufacture of custom-fitting surgical guides

This research was part of a long-term research project undertaken by the authors into the application of advanced design techniques to the needs of maxillofacial surgery. Advances in medical CT scanning have led to the development of computer-aided surgical planning. There are two competing methods of translating these computer plans to the operating theatre; navigation or templates (surgical guides). Whilst surgical guides had been demonstrated in the placement of oral implants, the guides had been made from plastic additive manufacture materials. These plastic materials posed problems due their fragility and difficulty in sterilisation. This research explored the design and manufacture implications of utilising metal Rapid/Additive Manufacturing (AM) process and materials. This article reported on the exploitation of a new manufacturing technique called Selective Laser Melting (SLM). Experiments were used to establish design parameters for the successful manufacture of surgical guides, including design considerations, build strategies, optimum orientation and support generation. Assessment of the guides produced by SLM in 316L Stainless Steel demonstrated that the finished items were fit for purpose and compared favourably to guides made using alternative techniques such as stereolithography. This work reports the world’s first successful production of surgical guides using SLM. This research also involved the world’s first application of SLM to the design and manufacture of surgical guides that incorporated osteotomy (cutting with a saw) as well as drilling. It has provided a foundation of knowledge that has led to further research that aims to create an economically viable commercial application of the techniques that can be adopted for widespread clinical application.