Innovative 3D reconstruction in oral and sinus surgery using advanced printing technologies

Abstract The aim of this paper is to provide an innovative approach to develop novel three-dimensional models of the paranasal sinuses in order to increase the surgical efficiency in oral and sinus surgery. The anatomic models are made from materials with special mechanical properties that mimic real human structures. The models can be used for pre-planning and training in functional endoscopic sinus surgery. The data from the CBCT (Cone beam computed tomography) scan was exported as an STL (stereolithography) file and then processed for 3D printing. A two-stage approach was used, firstly printing the sinus cavity as a rigid model to assess the geometric accuracy of the 3D reconstruction, and secondly a multi-material model with elastic properties encompassing the sinus structures as a hollow volume inside a parallelepipedal model. The preliminary tests using FESS instruments showed promising results towards the final goal to achieve an anatomic replica of the oral and sinus areas in terms of geometry and tissue elastic behaviour.