Missing facial parts computed by a morphable model and transferred directly to a polyamide laser-sintered prosthesis: an innovation study.

Mirroring of missing facial parts and rapid prototyping of templates have become widely used in the manufacture of prostheses. However, mirroring is not applicable for central facial defects, and the manufacture of a template still requires labour-intensive transformation into the final facial prosthesis. We have explored innovative techniques to meet these remaining challenges. We used a morphable model of a face for the reconstruction of missing facial parts that did not have mirror images, and skin-coloured polyamide laser sintering for direct manufacture of the prosthesis. From the knowledge gleaned from a data set of 200 coloured, three-dimensional scans, we generated a missing nose that was statistically compatible with the remaining parts of the patient's face. The planned prosthesis was manufactured directly from biocompatible skin-coloured polyamide powder by selective laser sintering, and the prosthesis planning system produced a normal-looking reconstruction. The polyamide will need adjustable colouring, and we must be able to combine it with a self-curing resin to fulfil the requirements of realistic permanent use.

Facial acquisition by dynamic optical tracked laser imaging: a new approach.

Three-dimensional capture of the surface of soft tissue is a desirable support for documentation and therapy planning in plastic and reconstructive surgery concerning the complex anatomy of the face, particularly cleft lip and palate (CLP). Different scanning systems are used for capturing facial surfaces. These systems are mostly based on a static linear measuring arrangement. Established systems work on the basis of coded white light or linear laser triangulation and digital stereophotogrammetric approaches. Shadowing effects occur with these devices. These effects may be avoided by a radical new approach first used in automotive industries that employs a mobile, flexible handheld laser scanner with simultaneous registration by optical tracking. The aim of this study was to assess the suitability of this scanner for surgical procedures on the human face in operating theatre. Five babies aged about 3 months with cleft deformities (one CLP, one bilateral CLP, three isolated cleft lips) were captured directly: twice preoperatively, twice postoperatively and twice after 7 days. An industrial standard specimen and two plaster cast masks of CLP babies were taken and subsequently measured to assess reliability and validity of the device. Masks were measured to reflect the complex surface of the cleft deformity. Data evaluation was done with respect to completeness of the data sets, as well as reliability and validity of the system. Missing data caused by shadowing could be avoided in all images. Even complex areas with undercuts could be reproduced completely and precisely with an accuracy in the sub-millimetre range.

3D surface measurement for medical application--technical comparison of two established industrial surface scanning systems.

In 3D mapping of flexible surfaces (e.g. human faces) measurement errors due to movement or positioning occur. Aggravated by equipment- or researcher-caused mistakes considerable deviations can result. Therefore first the appliances' precision handling and reliability in clinical environment must be established. Aim of this study was to investigate accuracy and precision of two contact-free 3D measurement systems (white light vs. laser). Standard specimens of known diameter for sphere deviation, touch deviation and plane deviation were tested. Both systems are appropriate for medical application acquiring solid data (