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Stereolithographic (SL) biomodelling is a relatively new technology that allows three‐dimensional (3D) computed tomography (CT) data to be used to generate accurate solid plastic replicas of biological structures (biomodels). A prospective trial to investigate the utility of biomodelling in palaeontology was performed. Seven fossil specimens were selected. Volumetric 3D reconstructions were generated on each specimen. The data of interest were edited and converted into a form acceptable for SL. SL uses a laser to selectively polymerize photosensitive resin to manufacture each biomodel. The biomodels were assessed for fidelity, internal morphology and for use in display and demonstration. Biomodelling was found to faithfully replicate the fossilized specimens. The most important variable affecting biomodel accuracy was the initial acquisition of 3D CT data. Biomodelling is intuitive, user‐friendly technology that facilitates morphological assessment and specimen reconstruction. Biomodelling allowed both internal and external features of fragile specimens to be safely replicated without risk.

Design methods for medical rapid prototyping (RP) of personalized cranioplasty implants are presented in this paper. These methods are applicable to model cranioplasty implants for all types of the skull defects including beyond‐midline and multiple defects. The methods are based on two types of anatomical data, solid bone models (STereoLithography files – STL) and bone slice contours (Initial Graphics Exchange Specification – IGES and StrataSys Layer files – SSL). The bone solids and contours are constructed based on computed tomography scanning data, and these data are generated in medical image processing and STL slicing packages.

Today, medical models can be made by the use of medical imaging systems through modern image processing methods and rapid prototyping (RP) technology. In ultrasound imaging systems, as images are not layered and are of lower quality as compared to those of computerized tomography (CT) and magnetic resonance imaging (MRI), the process for making physical models requires a series of intermediate processes and it is a challenge to fabricate a model using ultrasound images due to the inherent limitations of the ultrasound imaging process. The purpose of this paper is to make high quality, physical models from medical ultrasound images by combining modern image processing methods and RP technology.

A novel and effective semi‐automatic method was developed to improve the quality of 2D image segmentation process. In this new method, a partial histogram of 2D images was used and ideal boundaries were obtained. A 3D model was achieved using the exact boundaries and then the 3D model was converted into the stereolithography (STL) format, suitable for RP fabrication. As a case study, the foetus was chosen for this application since ultrasonic imaging is commonly used for foetus imaging so as not to harm the baby. Finally, the 3D Printing (3DP) and PolyJet processes, two types of RP technique, were used to fabricate the 3D physical models.

The physical models made in this way proved to have sufficient quality and shortened the process time considerably.

It is still a challenge to fabricate an exact physical model using ultrasound images. Current commercial histogram‐based segmentation method is time‐consuming and results in a less than optimum 3D model quality. In this research work, a novel and effective semi‐automatic method was developed to select the threshold optimum value easily.

To describe the development of a novel polyether(meth)acrylate‐based resin material class for stereolithography with alterable material characteristics.

A complete overview of details to composition parameters, the optimization and bandwidth of mechanical and processing parameters is given. Initial biological characterization experiments and future application fields are depicted. Process parameters are studied in a commercial 3D systems Viper stereolithography system, and a new method to determine these parameters is described herein.

Initial biological characterizations show the non‐toxic behavior in a biological environment, caused mainly by the (meth)acrylate‐based core components. These photolithographic resins combine an adjustable low Young's modulus with the advantages of a non‐toxic (meth)acrylate‐based process material. In contrast to the mostly rigid process materials used today in the rapid prototyping industry, these polymeric formulations are able to fulfill the extended need for a soft engineering material. A short overview of sample applications is given.

These polymeric formulations are able to meet the growing demand for a resin class for rapid manufacturing that covers a bandwidth from softer to stiffer materials.

This paper gives an overview about the novel developed material class for stereolithography and should be therefore of high interest to people with interest in novel rapid manufacturing materials and technology.

This paper describes computer‐aided design (CAD) and rapid prototyping (RP) systems for the fabrication of maxillofacial implant.

Design methods for medical RP of custom‐fabricated are presented in this paper. Helical computed tomography (CT) data were used to create a three‐dimensional model of the patient skull. Based on these data, the individual shape of the implant was designed in CAD environment and fabricate by RP process. One patient with a large mandible defect underwent reconstruction with individual prefabricated implant resulting from initial surgical failure with hand contoured reconstruction plate.

Results shows that the custom made implant fit well the defect. Overall, excellent mandible symmetry and stability were achieved with the custom made implants. The patient was able to eat. There was no saliva drooling after the reconstruction. The operating time was reduced.

The methods described above suffer from the expensive cost of RP technique.

This method allows accurate fabrication of the implant. The advantages of using this technique are that the physical model of the implant is fitted on the skull model so that the surgeon can plan and rehearse the surgery in advance and a less invasive surgical procedure and less time‐consuming reconstructive and an adequate esthetic can result.

The method improves the reconstructive surgery and reduces the risk of a second intervention, and the psychological stress of the patient will be eliminated.

The goal of rapid mechanical prototyping is to be able to quickly fabricate complex‐shaped, 3D parts directly from computer‐aided design models. The key idea of this novel technology is based upon decomposition of 3D computer models data into thin cross‐sectional layers, followed by physically forming the layers and stacking them up; “layer by layer technique.” This new method of modeling has raised many attentions in dentistry especially in the field of surgery and implantology. The purpose of this review study is to represent the historical development and various methods currently used for building dental appliances. It is also aimed to show the many benefits which can be achieved by using this new technology in various branches of dentistry.

The major existing resources, including unpublished data on the internet, were considered.

Although, creating 3D objects in a layered fashion is an idea almost as old as human civilization but, this technology has only recently been employed to build 3D complex models in dentistry. It seems that in near future many other methods will develop which could change traditional dental practices. It is advisable to include more unit hours in dental curriculums to acquaint dental students with the many benefits of this novel technology.

It is hard to believe that the routine dental techniques were affected by revolutionary concepts originally theorized by engineering methods. It is a reality that in future, most of the restorative disciplines will be fully revised and the computer methods be evolved to an extent where dentistry can be performed by computer‐assisted methods with optimum safety, simplicity, and reliability.

This paper aims to illustrate a number of instances where RP and associated technology has been successfully used for medical applications.

A number of medical case studies are presented, illustrating different uses of RP technology. These studies have been analysed in terms of how the technology has been applied in order to solve related medical problems.

It was found that RP has been helpful in a number of ways to solve medical problems. However, the technology has numerous limitations that have been analysed in order to establish how the technology should develop in the future.

RP can help solve medical problems, but must evolve if it is to be used more widespread in this field.

This paper has shown a number of new applications for RP, providing a holistic understanding how the technology can solve medical problems. It also identifies a number of ways in which the technology can improve in order to better solve such problems.

This study aims to provide an overview of rapid prototyping (RP) and shows the potential of this technology in the field of medicine as reported in various journals and proceedings. This review article also reports three case studies from open literature where RP and associated technology have been successfully implemented in the medical field.

Key publications from the past two decades have been reviewed.

This study concludes that use of RP-built medical model facilitates the three-dimensional visualization of anatomical part, improves the quality of preoperative planning and assists in the selection of optimal surgical approach and prosthetic implants. Additionally, this technology makes the previously manual operations much faster, accurate and cheaper. The outcome based on literature review and three case studies strongly suggests that RP technology might become part of a standard protocol in the medical sector in the near future.

The article is beneficial to study the influence of RP and associated technology in the field of medicine.

The purpose of this study was to develop and apply new physical heart defect models (PHDMs) that are patient-specific and color-coded with an optimized map.

Heart defect anatomies were segmented from medical images and reconstructed to form virtual models, which were then color-coded and rapid prototyped. The resulting PHDMs were used in a medical educational study to evaluate their pedagogical efficacy and in clinical case studies to investigate their utility in surgical planning.

A growing library of 36 PHDMs (including the most common defects) was generated. Results from the educational study showed that the PHDMs enabled uniquely effective learning, and the clinical case studies indicated that the models added value as surgical planning aids.

The education study involved a limited number of students, so future work should consider a larger sample size. The clinical case studies favored use of the PHDMs in surgical planning, but provided only qualitative support.

Workflow optimization is critical for PHDMs to be used effectively in surgical planning because some operations must be performed in emergently.

Because PHDMs have potential to influence surgeons’ actions as surgical planning aids, their use in that context must be thoroughly vetted.

The proposed models represent the first PHDMs that are patient-specific and fully color-coded with a standardized map optimized for the human visual system. The models enhanced medical education and facilitated effective surgical planning in this study.

Aims to investigate medical rapid prototyping (medical RP) technology applications and methods based on reverse engineering (RE) and medical imaging data.

Medical image processing and RE are applied to construct three‐dimensional models of anatomical structures, from which custom‐made (personalized) medical applications are developed.

The investigated methods were successfully used for design and manufacturing of biomodels, surgical aid tools, implants, medical devices and surgical training models. More than 40 medical RP applications were implemented in Europe and Asia since 1999.

Medical RP is a multi‐discipline area. It involves in many human resources and requires high skills and know‐how in both engineering and medicine. In addition, medical RP applications are expensive, especially for low‐income countries. These practically limit its benefits and applications in hospitals.

In order to transfer medical RP into hospitals successfully, a good link and close collaboration between medical and engineering sites should be established. Moreover, new medical applications should be developed in the way that does not change the traditional approaches that medical doctors (MD) were trained, but provides solutions to improve the diagnosis and treatment quality.

The presented state‐of‐the‐art medical RP is applied for diagnosis and treatment in the following medical areas: cranio‐maxillofacial and dental surgery, neurosurgery, orthopedics, orthosis and tissue engineering. The paper is useful for MD (radiologists and surgeons), biomedical and RP/CAD/CAM engineers.