We talk about it with Nils Winkes, EMEA Medical Sales Manager at Stratasys, whom we thank for his collaboration on this new BIO3DNEWS.

Considering the concrete contribution of 3D printing in the production of medical instruments, it is right to begin by underlining the difference between models for preoperative surgical use – or for medical training – 3D prototypes for development of clinical instruments and the final production of supports for postoperative treatment or recovery.

3D Models

The first are ultra-realistic and anatomically perfect three-dimensional models, which reproduce human limbs or organs, created starting from diagnostic images (CT or MRI) on the exact conformation of the patient and his pathology. These 3D models are capable of reproducing the tissue consistency of human body and can be incised, perforated or sutured. They can reproduce hollow-lumen parts, such as venous or arterial sections, allowing the passage of fluids and are essential for preoperative practice, as they allow the surgical intervention to be tested before entering the operating room, significantly increasing the chances of a positive outcome.

3D prototypes are 3D reproductions useful for evaluating the structure of clinical instruments, before they are produced. It should be noted, however, that today 3D printers also allow the direct production (without prototypes) of sterilizable and/or disposable instruments for minimally invasive surgery, surgical templates and guides, thanks to their ability to work with biocompatible and autoclavable materials.

Finally, for the orthopedic and dental sector, there is the possibility of 3D printing customized prostheses and implants, which improve post-operative recovery by acting as custom supports, developed – again – on the exact physiognomy and needs of the individual patient.

Pre-operative surgical models

But now we want to focus on models for pre-operative surgical use and so we go into detail together with Nils Winkes, EMEA Medical Sales Manager at Stratasys.

Which Stratasys 3D printing technologies do you recommend choosing to quickly and efficiently create 3D models suitable for pre-operative surgical training?

“You should definitely opt for one of the 3D printers developed by Stratasys for digital anatomical reproduction. Depending on the print size needed, the space available and the color/material combination needs, you can opt for a J5 3D printer or a J850 solution, both with DAP – Digital Anatomy Printer technology.“

How does the additive manufacturing process, especially for 3D models for pre-operative surgical use, occur with these technologies?

“Good question: let’s start by saying that with the wide range of solutions available, both in terms of materials and technologies, we can cover almost every stage of 3D model development.

We start with design and preparation: this phase begins with creation of a digital model of the anatomical structure, using medical imaging data such as CT or MRI scans. This model is then refined using specialized software to ensure accuracy and detail. Then comes the selection of materials, and here Stratasys offers a range of materials that perfectly mimic the properties of human tissue. These materials are selected based on the specific clinical application, thus differentiating the choice whether it is a surgical planning model, a prosthetics or a customized medical device.

Then comes 3D printing, which is where the refined digital model is sent to Stratasys’ Digital Anatomy printer, powered by PolyJet technology. This printer ‘builds’ our model layer by layer, depositing material with high precision to create detailed, lifelike anatomical structures.

And it ends with the post processing phase: once the 3D printing is completed, model is subjected to post processing phases such as cleaning and possible polishing, to improve its appearance. This ensures that the model is ready for clinical use.

The 3D printed model is now ready to be used for various clinical purposes, including surgical planning and medical education. These models help improve surgical outcomes, enhance education, and provide increasingly personalized healthcare solutions.
This process enables the creation of highly accurate and functional medical models that can significantly benefit patient care and clinical practices.

Which materials are most functional for the creation of 3D models for pre-operative surgical use? And what are the possible combinations of materials, in a multi-printing process?

“For example, we can print in transparent, full-color, biocompatible, flexible full-color or flexible single color. Or with Matrix materials, which mimic biomechanical properties in an excellent way. You can even combine up to 5 + 1 (a support material) different materials on the J5 DAP 3D printer or up to 7 +1 different materials in one printing process with the J850 DAP“.

What are the regulations that a 3D printed medical model must comply with? What characteristics of the 3D model are necessary for it, to respond effectively to the tests? And what regulations does the 3D model printed with Stratasys systems guarantee to comply with?

“Usually, a 3D model is only used to verify specific conditions or test compliance with particular needs, so there are no specific requirements to meet. But as Stratasys we can add value to this process thanks to materials such as MED 610 resin or Vero Contact Clear solution, which have biocompatibility from ISO 10-993 and therefore can be used for surgical guides, with non-permanent external contact with skin and mucous membranes. Our 3D printers also have Medical Product Standard certifications such as ISO 13485″.

Conclusion

We conclude by highlighting how 3D printing in the medical and surgical field continues to evolve rapidly, offering increasingly advanced opportunities for the personalization of treatments, the efficiency of surgical practice and the reduction of costs. All this, with a significant impact on the effectiveness of care and the quality of clinical work.