Patient-specific 3D printed plates improve stability of Le Fort 1 osteotomies in vitro.

PURPOSE: Selective laser melting used to manufacture patient-specific 3D-printed (PSP) plates is a delicate process, which may introduce weakened areas in the plates, with risk of fracture. This in vitro study's purpose was to test the ability of PSP plates to stabilize Le Fort I osteotomies compared with manually adapted stock plates. The study's objectives were to measure the force needed to compress the osteotomy and evaluate whether the PSP plates would break during compression. MATERIALS AND METHODS: This controlled in vitro study evaluated the maxillary stability using the clinical data from 7 patients. The virtually planned maxillary reposition was 3D-printed in 2 copies, and the osteotomy gap was fixated by either PSP plates or stock plates. The models were compressed until the Le Fort I osteotomy gap was eliminated. The primary outcome was the force needed to compress the model. The primary predictor variable was a comparison between PSP and stock plates. Secondary outcome measurements were the slope of elastic modulus, yield point, and force needed for 2 mm compression. Statistical testing was performed by Wilcoxon signed-rank test with significance level at P ≤ 0.05. RESULTS: The PSP plates performed better than stock plates in all outcome measurements. None of the plates broke during compression despite forces of more than 4000 N. The first point of failure in PSP plates was the first screw cranial to the osteotomy. In comparison, the first point of failure in stock plates was in the plates' bend at the osteotomy. CONCLUSION: In this in vitro setup, the Le Fort I osteotomies fixated with PSP plates were more stable than the osteotomies fixated with conventional stock plates. No adverse effects occurred during testing of PSP plates; thus, PSP plates seem to be a safe alternative to stock plates and may even be preferable.

Simple additive manufacturing of an osteoconductive ceramic using suspension melt extrusion.

OBJECTIVE: Craniofacial bone trauma is a leading reason for surgery at most hospitals. Large pieces of destroyed or resected bone are often replaced with non-resorbable and stock implants, and these are associated with a variety of problems. This paper explores the use of a novel fatty acid/calcium phosphate suspension melt for simple additive manufacturing of ceramic tricalcium phosphate implants. METHODS: A wide variety of non-aqueous liquids were tested to determine the formulation of a storable 3D printable tricalcium phosphate suspension ink, and only fatty acid-based inks were found to work. A heated stearic acid-tricalcium phosphate suspension melt was then 3D printed, carbonized and sintered, yielding implants with controllable macroporosities. Their microstructure, compressive strength and chemical purity were analyzed with electron microscopy, mechanical testing and Raman spectroscopy, respectively. Mesenchymal stem cell culture was used to assess their osteoconductivity as defined by collagen deposition, alkaline phosphatase secretion and de-novo mineralization. RESULTS: After a rapid sintering process, the implants retained their pre-sintering shape with open pores. They possessed clinically relevant mechanical strength and were chemically pure. They supported adhesion of mesenchymal stem cells, and these were able to deposit collagen onto the implants, secrete alkaline phosphatase and further mineralize the ceramic. SIGNIFICANCE: The tricalcium phosphate/fatty acid ink described here and its 3D printing may be sufficiently simple and effective to enable rapid, on-demand and in-hospital fabrication of individualized ceramic implants that allow clinicians to use them for treatment of bone trauma.