Printer Friendly

3D custom-made implants for the reconstruction of craniofacial bone defects. Evaluation at seven years of use.

1. INTRODUCTION

Cranial vault defects result from trauma, infection, tumor ablation or cerebral decompression procedures. Cranial defects produce not only aesthetic but also functional alterations. The so-called "syndrome of the trephined" can be encountered in such patients (Dujovny et al., 1999). Functional alterations are often observed due to the changes in cerebral blood-flow velocity.

Thus, the main purpose of a cranioplasty is not only cosmetic repair but also improving the neurological status. Various materials have been used to fill defects in the cranial vault, such as metal, xenografts, autografts, and allografts (Durand et al., 1997). Polymethylmethacrylate (PMMA PMMA polymethyl methacrylate. ) is the one mostly used for cranioplasty between the plastics. However, the complexity of reconstruction increases proportionally with the size of the [defect.sup.11] as well as with the location which raise the necessity to reproduce a complex anatomical shape. Three-dimensional imaging and rapid prototyping techniques associated with the use of alloplastic materials allow construction of a custom-made implant preoperatively. The defect is repaired symmetrically even in thickness. In this paper a technique of custom implant manufacturing using polymethylmethacrylate casted in silicone rubber mould, that standed the test of time, is presented along with its critical review.

2. MATERIAL AND METHOD

The calvarial defects of eighteen patients and four facial skeleton defects were repaired using custom made implants. Defects developed secondary to small bone fragments removal after comminuted fractures, infection-driven loss of the bone flaps elevated for decompression craniotomy Craniotomy Definition

Surgical removal of part of the skull to expose the brain.
Purpose

A craniotomy is the most commonly performed surgery for brain tumor removal.
, bone tumor resection and vicious consolidation of facial fractures.

To produce the custom made implants the patients underwent a spiral CT scan of the head (Siemens Somatom; Erlangen, Germany). A virtual model of the skull was obtained by means of three-dimensional reconstruction (MIMICS[R], Materialise N.V., Leuven, Belgium). The virtual 3D model for the patient specific implant was obtained by designing it with Freeform Modelling Plus[R] v. 9.0 (Sensable, USA).

Using selective laser sintering See laser sintering and 3D printer.  (SLS (Selective Laser Sintering) See laser sintering and 3D printing. ) and 3D printing (Sinter Station 2000, 3D System, Darmstadt, Germany, Eden 330, Objet Geometries, Rehovot, Israel), both virtual models (defect and plate) were transformed into physical models. The plate fitted perfectly into the defect.

The pattern of the implant was used to make a silicone rubber mould. Radiopaque bone cement (Surgical Simplex[R] P, Stryker Howmedica Osteonics, Limerick, Ireland) made of polymethylmethacrylate was casted in the silicone rubber mould and pressed into form.

After unmoulding, the margins of the final custom made implant were slightly manually processed in order to eliminate the excess and to drill holes for fixation. On cranioplasty plate's surface, holes were drilled in order to prevent development of an epidural haematoma Noun 1. haematoma - a localized swelling filled with blood
hematoma

intumescence, intumescency - swelling up with blood or other fluids (as with congestion)
. Before surgery, the cranioplasty plates were sterilized using ethylene-oxide.

3. RESULTS

Under general anesthesia the bony defect was exposed. The custom made plates were applied. Fourteen (77.7%) of them fitted perfectly and needed no further processing (Fig. 1). Four (33.3%) of the plates were, in some areas, smaller than the bony defect. This was finally judged as being due to a longer time interval between CT scanning and cranioplasty operation. Moreover, the imprecise fitting of the plate was present in all cases (number) where the CT scanning was performed earlier than 6 months after the initial surgery. Bone remodeling, by resorption resorption /re·sorp·tion/ (re-sorp´shun)
1. the lysis and assimilation of a substance, as of bone.

2. reabsorption.


re·sorp·tion
n.
, of the defect margins (healing) was the main factor incriminated in this mechanism. One orbital implant (25 %) was larger then needed, determining exoftalmia. It had been adapted intraoperatively.

[FIGURE 1 OMITTED]

Fore security reasons the plates were fixed with 2.0 silk sutures to the bony margins of the defect and screws were used to fix the facial implants.

There was only one intra-operative complication in a case where the brain herniated through the bony defect from the beginning, due to some cystic degeneration. Thus, the plate was pressed with some force to fit the defect and the result was a fixed midriasis. Plate was immediately removed and the patient recovered. Few days later the plate was applied again leaving a gap between the bone and the plate. In all cases there were no problems of covering the plates with the skin. Starting intraoperatively, an antibiotic treatment was conducted for the next ten days. In the recovery period, the healing process was eventless. There were no infectious episodes or wound dehiscences encountered and the patients were discharged on the seventh day postoperatively after stitch removal. Follow-up was one, six months and then yearly after the operation, with clinical and CT examination. Clinically, no complications were noted, patients tolerating well the cranioplasty plate. The esthetical aspect of all the patients operated was significantly improved (Fig. 2). The symmetry was perfectly obtained in all cases (Fig. 3). CT examination showed the implants in place with no meningeal me·nin·ge·al
adj.
Of, relating to, or affecting the meninges.



meningeal

pertaining to the meninges.


meningeal hemorrhage
 or soft tissue reactions.

[FIGURE 2 OMITTED]

[FIGURE 3 OMITTED]

4. DISCUSSION

To repair large, complex, skull defects one can choose either to reconstruct the vaults strictly intra-operatively or to prepare a so called "custom made cranial implant," prior to the operation. The disadvantages of intra-operative repair are time-consuming, increasing risk to the patient, insufficient protection from trauma and infection, often resulting in suboptimal Suboptimal
A solution is called suboptimal if a part of the solution has been optimized without regards to the overall objective.
 cosmesis. However, custom made cranioplasty implants have the advantages of a reduced operative time, less invasive surgery, improved cosmetic results, faster recuperation recuperation /re·cu·per·a·tion/ (-koo?per-a´shun) recovery of health and strength.
recuperation,
n the process of recovering health, strength, and mental and emotional vigor.
, and reduced costs due to a short operative time (Zeilhofer et al.: 1997, Rotaru 2001).

Custom made implants manufactured using rapid prototyping techniques have been introduced already (Binder & Kaye 1994, Eufinger et al., 1995, Chiarini et al., 2004). However, there are some problems in reproducibility. Various authors have used a plaster mould (Chiarini et al., 2004, D'Urso et al. 2004). The method presented here used mainly a silicone rubber mould. Compared to plaster, the main advantage of silicone rubber is that it allows preservation of very thin details of the implant (e.g. margins) during unmoulding. Preserving the thin margins provided a better stabilization. Chiarini et al. (2004) recommended the acrylic prosthesis prosthesis (prŏs`thĭsĭs): see artificial limb.
prosthesis

Artificial substitute for a missing part of the body, usually an arm or leg.
 to overlap the bone surroundings by 10 mm in order to avoid a possible incorrect prefabrication prefabrication, in architectural construction, a technique whereby large units of a building are produced in factories to be assembled, ready-made, on the building site. The technique permits the speedy erection of very large structures.  of the plate. In large defects such as presented above, titanium mesh must be two-directionally bent to mimic the anatomical shape. When doing this, sharp edges are generated on the surface of the mesh. This, in fact, happens to every rigid plate that is simultaneously bent in two directions. Casted titanium preformed plates reshape well the surface of the skull but they do not repair the defect. For stability reasons, they must overlap the margins of the defect and must be fixed using osteosynthesis material.

In the future, selective laser melted titanium implants can combine the advantages of the titanium with the ones of 3D modeling by rapid prototyping, for the reconstruction of the bone defects. This technology is now emerging in the medical field.

5. CONCLUSIONS

Custom made cranial implants prepared in a silicone-rubber mould are particularly useful for repairing large and complex-shaped defects and have many advantages when compared with intraoperative production.

6. ACKNOWLEDGEMENTS

The research was partially funded through BIOMAPIM research project (CNCSIS CNCSIS Consiliul National al Cercetarii Stiintifice din Invatamantul Superior (Romania) , PN II Idei).

7. REFERENCES

Binder W J, Kaye A.: Reconstruction of posttraumatic posttraumatic /posttrau·mat·ic/ (post?traw-mat´ik) occurring as a result of or after injury.

post·trau·mat·ic
adj.
Following or resulting from injury or trauma.
 and congenital facial deformities with three-dimensional computer-assisted custom-designed implants. Plastic and Reconstructive Surgery. 1994, 94: 775-785

Chiarini L, Figurelli S, Pollastri G, et al.: Cranioplasty using acrylic material: a new technical procedure. J Craniomaxillofac Surg 2004, 32: 5-9

D'Urso PS, Earwaker WJ, Barker TM, et al.: Custom cranioplasty using stereolithography and acrylic. Br J Plast Surg 2004, 53: 200-204

Dujovny M, Agner C, Aviles A.: Syndrome of the trephined: theory and facts. Crit Rev Neurosurg 1999, 24: 271-278

Durand JL, Renier D, Marchac D: The history of cranioplasty. Ann Chir Plast Esthet 1997, 42: 75-83

Eufinger H, Wehmoeller M, Harders A, et al.: Prefabricated prostheses Prostheses
A synthetic object that resembles a missing anatomical part.

Mentioned in: Microphthalmia and Anophthalmia
 for the reconstruction of skull defects. Int J Oral Maxillofac Surg 1995, 24: 104-110

Rotaru AH: Avantajele si dezavantajele utilizarii modelelor tridimensionale medicale. In: Rotaru AH: Reconstructii si Modele Tridimensionale Medicale. Ed. Casa Cartii de Stiinta, Cluj-Napoca, 2001. p. 99-100

Zeilhofer HF, Sader R, Fruh HJ, et al.: Moglichkeiten und Indikationsbereiche der Kohlenstoffaserverstarkten Kunststoffe zur Herstellung individueller Implantate fur die Rekonstruktion des Gesichts- und Hirnschadels. Biomedizinische Technik, 1997, 42, 361-362
COPYRIGHT 2010 DAAAM International Vienna
No portion of this article can be reproduced without the express written permission from the copyright holder.
Copyright 2010 Gale, Cengage Learning. All rights reserved.

 Reader Opinion

Title:

Comment:



 

Article Details
Printer friendly Cite/link Email Feedback
Author:Rotaru, Horatiu; Stan, Horatiu; Schumacher, Ralf; Baciut, Grigore; Chezan, Horea; Kim, Seong-Gon
Publication:Annals of DAAAM & Proceedings
Article Type:Report
Geographic Code:4EXRO
Date:Jan 1, 2010
Words:1346
Previous Article:Investigation of the particular crystallization behaviour of semi- crystalline thermoplastic powders processed by selective laser sintering.
Next Article:Evaluation of innovative techniques for dental crowns manufacturing.
Topics:

Terms of use | Copyright © 2014 Farlex, Inc. | Feedback | For webmasters