Use of 3D Printing for Preoperative Surgical Planning: Converting CT Scan Data to a Printed 3D Model

Patient presents with a history of significant femur deformity requiring surgical revision. Goal is to use 3D printing to create a replica of the femur for preop planning. CT scan data was taken and converted to data compatible for 3D printing. The 3D printed model was then used to test an osteotomy cut to confirm the result prior to surgery.

3D Printing in Preoperative Planning: Converting CT Data to a 3D Printed Model Dallin Sudbury, OTR; Katy Fu, NP; David Rothberg, MD University of Utah Health Background Multiplanar Malunion surgeries are complex due to altered anatomy of the bone and the complex interactions of the bone with the implant. Accurate preoperative planning is essential for optimal outcomes. CT Scan/DICOM Data is converted to 3D model Model is cleaned, reviewed and cut to desired length • Pre-op planning and execution of osteotomy. • Assessment of bone defect dimensions and morphology. • Prediction of potential intraoperative challenges. • Enhanced patient education of procedure. Outcomes Traditional imaging lacks crucial tactile and spatial information. Therefore, identifying methods which can allow a more tangible product prior to surgical intervention could be helpful. This project demonstrates the use of a patient-specific 3D-printed femur model, derived from CT data, that was used for preoperative planning in a revision surgery. Benefits Model is prepared for printing • Clinical outcomes are ongoing but thus far are excellent. • Future use of 3D modelling will continue to be used for preoperative planning. Final model is printed for use Alemayehu DG, Zhang Z, Tahir E, Gateau D, Zhang DF, Ma X. Preoperative Planning Using 3D Printing Technology in Orthopedic Surgery. Biomed Res Int. 2021 Oct 12;2021:7940242. doi: 10.1155/2021/7940242. PMID: 34676264; PMCID: PMC8526200. Portnoy Y, Koren J, Khoury A, Factor S, Dadia S, Ran Y, Benady A. Three-dimensional technologies in presurgical planning of bone surgeries: current evidence and future perspectives. Int J Surg. 2023 Jan 1;109(1):3-10. doi: 10.1097/JS9.0000000000000201. PMID: 36799780; PMCID: PMC10389328.