3D printed cutting guides lead to "improved" cancer outcomes

Stratasys, a polymer 3D printing solutions manufacturer, has said that the University Hospital Birmingham in England is delivering improved outcomes for head and neck cancer patients, with the hospital reporting reduced surgery times of up to three hours using tailored, 3D printed cutting guides.

This is attributed to the integration of a Stratasys J5 MediJet 3D printer that enables the hospital to create accurate, patient-specific cutting guides ahead of operations, transforming the way tumours are removed from head and neck cancer patients. Previously, these would have been created by cutting and bending a piece of metal by hand while the patient was on the operating table, resulting in a time-consuming process with a large margin for error.

Using 3D printing, the surgical team can now produce accurate devices using patient scans, with a resolution of within 150 microns, helping to support surgical outcomes. These are produced in Biocompatible Clear MED610; a rigid, transparent resin suitable for applications requiring long-term contact (more than 30 days) with intact skin and limited contact (up to 24 hours) with tissue, bone, or mucosal membranes.

Stefan Edmondson, consultant clinical scientist (Reconstructive Science) at the hospital, said: “In addition to saving up to three hours of surgery time, 3D printing also enables much better surgical planning. Using patient scans, the team is able to create 3D visualisations based on the distinct anatomy of each patient – and then leverage 3D printing technology to produce both anatomical models and personalised surgical cutting guides ahead of the actual operation.

“This capability means we can not only accurately predict the surgery before it’s done, but that we have the tools to ensure that the meticulous pre-surgical planning can be executed with the utmost precision. The surgical team is also much better prepared and the patient is far more at ease, as we can talk through the process and expected outcomes prior to going into the operating theatre.”

According to the hospital, taking a segment of a patient’s fibula and moulding it into the exact shape and size to transplant into the target area within the head or neck, while ensuring bone tissue is kept alive, is a highly complex process in which 3D printing really demonstrates superior capabilities over conventional methods.

Edmondson added: “In this scenario, if the angles you’re cutting at aren’t absolutely perfect, the bone won’t fit and there will be a higher tendency for the body to reject it, leading to significant discomfort for the patient. Thankfully, the 3D printed cutting guides are accurate to micron level, ensuring the fibula is cut to the best possible fit for our patients.”