Medical Modeling

The Application of Advanced Design and Additive Manufacturing Techniques in Medicine

3rd Edition - June 8, 2024
Authors: Richard Bibb, Dominic Eggbeer, Abby Paterson, Mazher Iqbal Mohammed
Language: English
Paperback ISBN:
9 7 8 - 0 - 3 2 3 - 9 5 7 3 3 - 5
eBook ISBN:
9 7 8 - 0 - 3 2 3 - 9 5 7 3 4 - 2

Medical Modelling: The Application of Advanced Design and Rapid Prototyping Techniques in Medicine, Third Edition provides readers with a thorough update of the core conten… Read more

Purchase options

LIMITED OFFER

Save 50% on book bundles

Immediately download your ebook while waiting for your print delivery. No promo code needed.

Institutional subscription on ScienceDirect

Request a sales quote

Medical Modelling: The Application of Advanced Design and Rapid Prototyping Techniques in Medicine, Third Edition provides readers with a thorough update of the core contents, along with key information on innovative imaging techniques, additive manufacturing technologies, and a range of applied case studies. This comprehensive new edition includes new coverage of advanced technologies, such as selective laser melting, electron beam melting, multi jet fusion, and more. The extensive section of peer-reviewed case studies is thoroughly updated and includes additional clinical examples, describing the practical applications of advanced design technologies in surgical, prosthetic, orthotic, dental and research applications.

Finally, the book explores the future potential of medical modeling, such as in simulations for training, the development of new medical devices, and more.

Cover image
Title page
Table of Contents
Copyright
About the authors
Preface
Acknowledgements
Chapter 1. Introduction
1.1. Background
1.2. The human form
1.3. Basic anatomic terminology
1.4. Technical terminology
Chapter 2. Medical imaging
2.1. Introduction to medical imaging
2.2. Computed tomography
2.3. Cone beam computed tomography
2.4. Magnetic resonance
2.5. Noncontact surface scanning
2.6. Medical scan data
2.7. Point cloud data
2.8. Media
2.9. Summary
Chapter 3. Working with medical scan data
3.1. Image segmentation
3.2. Using CT data: Worked examples
3.3. Point cloud data operations
3.4. Two-dimensional formats
3.5. Pseudo 3D formats
3.6. True 3D formats
3.7. File management and exchange
3.8. Summary
Chapter 4. Physical reproduction
4.1. Introduction to additive manufacturing
4.2. Vat polymerization
4.3. Material extrusion
4.4. Powder bed fusion
4.5. Material jetting
4.6. Computer numerical controlled machining
4.7. Cleaning and sterilizing medical models
4.8. Summary
Chapter 5. Case studies
5.1. Introduction
Part 5.1. Implementation
Chapter 5.1. Implementation case study 1: Computed tomography guidelines for medical modeling using additive manufacturing techniques
5.1.1. Introduction
5.1.2. CT guidelines for medical modeling
5.1.3. Conclusion
Chapter 5.2. Implementation case study 2: The evolving development of a collaborative service: Organizational, technical, and regulatory considerations
5.2.1. Introduction
5.2.2. The early years of collaboration—Establishing a joint medical modeling service
5.2.3. Service evolution toward greater in-hospital capability
5.2.4. Bringing greater design expertise and guide production capability in-hospital
5.2.5. Evolving regulatory considerations
Chapter 5.3. Implementation case study 3: Medical additive manufacturing technologies: State of the art and current limitations for application in oral and maxillofacial surgery
5.3.1. Introduction
5.3.2. 3D image acquisition and processing for MRP
5.3.3. Rapid prototyping technologies
5.3.4. Medical rapid prototyped model artifacts
5.3.5. Conclusion
Part 5.2. Surgical applications
Chapter 5.4. Surgical application case study 1—Planning osseointegrated implants using computer-aided design and additive manufacturing
5.4.1. Introduction
5.4.2. The proposed approach
5.4.3. Scanning problems
5.4.4. Software problems
5.4.5. An illustrative case study
5.4.6. Results
5.4.7. Benefits and future development
Chapter 5.5. Surgical applications case study 2—Rapid manufacture of custom fitting surgical guides
5.5.1. Introduction
5.5.2. Methods
5.5.3. Case study
5.5.4. Results
5.5.5. Discussion
5.5.6. Conclusions
Chapter 5.6. Surgical application case study 3—The use of a reconstructed 3D solid model from CT to aid the surgical management of a total knee arthroplasty
5.6.1. Introduction
5.6.2. Materials and methods
5.6.3. Postoperative management and follow up
5.6.4. Discussion
Chapter 5.7. Surgical application case study 4—The custom-made titanium orbital floor prosthesis in reconstruction for orbital floor fractures
5.7.1. Introduction
5.7.2. Technique
5.7.3. Case report
5.7.4. Conclusion
Chapter 5.8. Surgical application case study 5—The use of 3D technology in the multidisciplinary management of facial disproportion
5.8.1. Introduction
5.8.2. Materials and method
5.8.3. Results
5.8.4. Discussion
Chapter 5.9. Surgical applications case study 6—An appropriate approach to computer-aided design and manufacture of reconstructive implants
5.9.1. Introduction
5.9.2. Case 1—Orbital rim augmentation implant
5.9.3. Case 2—Orbital floor implant incorporating placement guide
5.9.4. Case study 3—Multipart reconstruction
5.9.5. Case 4—Posttraumatic zygomatic osteotomy and orbital floor reconstruction
Chapter 5.10. Surgical application case study 7—Computer-aided planning and additive manufacture for complex, mid-face osteotomies
5.10.1. Introduction
5.10.2. Methods
5.10.3. Results
5.10.4. Discussion
5.10.5. Conclusions
Chapter 5.11. Surgical applications case study 8—Virtual surgical planning and development of a patient-specific resection guide for treatment of distal radius osteosarcoma
5.11.1. Introduction
5.11.2. Methods
5.11.3. Results
5.11.4. Conclusion
Part 5.3. Prosthetic applications
Chapter 5.12. Prosthetic rehabilitation applications case study 1—An investigation of three-dimensional scanning of human body surfaces and its use in the design and manufacture of prostheses
5.12.1. Introduction
5.12.2. Methods
5.12.3. Results
Chapter 5.13. Prosthetic rehabilitation applications case study 2—Producing burns therapy conformers using noncontact scanning and additive manufacturing
5.13.1. Introduction
5.13.2. Methods
5.13.3. Results
5.13.4. Discussion
5.13.5. Conclusions
Chapter 5.14. Prosthetic rehabilitation applications case study 3—An appropriate approach to computer-aided design and manufacture of cranioplasty plates
5.14.1. Introduction
5.14.2. First case
5.14.3. Second case
5.14.4. Third case—Press tool design
5.14.5. Fourth case—Implant design for metal AM fabrication
5.14.6. Fifth case—Implant design for PEEK AM fabrication
5.14.7. Future development and benefits
Chapter 5.15. Prosthetic rehabilitation applications case study 4—Evaluation of advanced technologies in the design and manufacture of an implant-retained facial prosthesis
5.15.1. Introduction
5.15.2. Existing facial prosthetics technique
5.15.3. Review of advanced technologies in facial prosthetics
5.15.4. Case 1
5.15.5. Case 2
5.15.6. Results
5.15.7. Discussion
5.15.8. Conclusions
Chapter 5.16. Prosthetic rehabilitation applications case study 5—Additive manufacturing technologies in soft tissue facial prosthetics: Current state of the art
5.16.1. Introduction
5.16.2. Methodology
5.16.3. Summary of case studies
5.16.4. Discussion
5.16.5. AM specification
5.16.6. Conclusions
Chapter 5.17. Prosthetic rehabilitation applications case study 6—Evaluation of direct and indirect additive manufacture of maxillofacial prostheses using additive manufacturing
5.17.1. Introduction
5.17.2. Methods
5.17.3. Results
5.17.4. Discussion
5.17.5. Conclusions
Acknowledgements
Chapter 5.18. Prosthetic rehabilitation applications case study 7—Computer-aided methods in bespoke breast prosthesis design and fabrication
5.18.1. Introduction
5.18.2. Methods
5.18.3. Discussion
5.18.4. Conclusions
Chapter 5.19. Prosthetic rehabilitation applications case study 8—Immediate nasal prosthesis following rhinectomy
5.19.1. Introduction
5.19.2. Methods
5.19.3. Discussion
5.19.4. Conclusions
Chapter 5.20. Prosthetic rehabilitation applications case study 9—Applications of 3D topography scanning and multimaterial additive manufacturing for facial prosthesis development and production
5.20.1. Introduction
5.20.2. Experimental
5.20.3. Results
5.20.4. Conclusions
Chapter 5.21. Prosthetic rehabilitation applications case study 10—Advanced auricular prosthesis development by 3D modeling and multimaterial printing
5.21.1. Introduction
5.21.2. Experimental
5.21.3. Results
5.21.4. Conclusions
Chapter 5.22. Prosthetic rehabilitation applications case study 11—Augmented patient-specific facial prosthesis production using medical imaging modeling and 3D printing technologies for improved patient outcomes
5.22.1. Introduction
5.22.2. Experimental
5.22.3. Results
5.22.4. Conclusions
Chapter 5.23. Prosthetic rehabilitation applications case study 12—Customized design and development of patient-specific 3D printed whole mandible implant
5.23.1. Introduction
5.23.2. Methodology
5.23.3. Results
5.23.4. Conclusions
Part 5.4. Orthotic applications
Chapter 5.24. Orthotic applications case study 1—A review of existing anatomic data capture methods to support the mass customization of wrist splints
5.24.1. Introduction
5.24.2. Data acquisition methods
5.24.3. Contact data acquisition
5.24.4. Conclusion and future work
Chapter 5.25. Orthotic applications case study 2—comparison of additive manufacturing systems for the design and fabrication of customized wrist splints
5.25.1. Introduction
5.25.2. Aim and objectives
5.25.3. Method
5.25.4. Results
5.25.5. Conclusions and future work
Chapter 5.26. Orthotic applications case study 3—Evaluation of a digitized splinting approach with multiple-material functionality using additive manufacturing technologies
5.26.1. Introduction
5.26.2. Research aim and objectives
5.26.3. Methods
5.26.4. Results and discussion
5.26.5. Future work
Chapter 5.27. Orthotic applications case study 4—Digitization of the splinting process: development of a CAD strategy for splint design and fabrication
5.27.1. Introduction
5.27.2. Current splinting techniques
5.27.3. Experimental procedures
5.27.4. Conclusion
Chapter 5.28. Orthotic applications case study 5—Evaluation of a refined three-dimensional computer-aided design workflow for upper extremity splint design to support additive manufacture
5.28.1. Introduction
5.28.2. Method
5.28.3. Results and discussion
5.28.4. Conclusions and further work
Chapter 5.29. Orthotic applications case study 6—Design optimization of a thermoplastic splint
5.29.1. Introduction
5.29.2. Original orthotic assessment
5.29.3. Methodology
5.29.4. Orthotic design
5.29.5. Manufacturing
5.29.6. Results
5.29.7. Manufacturing
5.29.8. Discussion and future work
5.29.9. Conclusion
Chapter 5.30. Orthotic applications case study 7—Design and additive manufacturing of a patient-specific polymer thumb splint concept
5.30.1. Introduction
5.30.2. Existing thumb splint fabrication
5.30.3. Methodology
5.30.4. Results
5.30.5. Conclusion
Chapter 5.31. Orthotic applications case study 8—Digital design and fabrication of a controlled porosity, personalized lower limb ankle foot orthosis
5.31.1. Introduction
5.31.2. Material and methods
5.31.3. Results and discussion
5.31.4. Conclusions
Chapter 5.32. Orthotic applications case study 9—A review of 3D printed patient-specific immobilization devices in radiotherapy
5.32.1. Introduction
5.32.2. Method
5.32.3. Results
5.32.4. Discussion
Chapter 5.33. Orthotic applications case study 10—case reports of three-dimensional printed assistive technology
5.33.1. Introduction
5.33.2. Three-dimensional printed assistive technology
5.33.3. Case study: Power mobility wheelchair user interface
5.33.4. 3D printing in mobility for recreation and leisure
5.33.5. Adapting the design for another user
5.33.6. Small design changes for a second-edition trough
5.33.7. Conclusion
Part 5.5. Dental applications
Chapter 5.34. Dental applications case study 1—the computer-aided design and additive manufacture of removable partial denture frameworks
5.34.1. Introduction
5.34.2. Materials and methods
5.34.3. Conclusions
Chapter 5.35. Dental applications case study 2—trial fitting of a removable partial denture framework made using computer-aided design and additive manufacturing
5.35.1. Introduction
5.35.2. Methods
5.35.3. Results
5.35.4. Discussion
5.35.5. Conclusions
Chapter 5.36. Dental applications case study 3—direct additive manufacture of removable partial denture frameworks
5.36.1. Introduction
5.36.2. Methodology
5.36.3. Results
5.36.4. Discussion
5.36.5. Conclusions
Chapter 5.37. Dental applications case study 4—A comparison of plaster, digital, and reconstructed study model accuracy
5.37.1. Introduction
5.37.2. Materials and methods
5.37.3. Results
5.37.4. Discussion
5.37.5. Conclusions
5.37.6. Future work
Contributors
Chapter 5.38. Dental applications case study 5—Design and fabrication of a sleep apnea device using CAD/AM technologies
5.38.1. Introduction
5.38.2. Methods and materials
5.38.3. Results
5.38.4. Discussion
5.38.5. Conclusion
Chapter 5.39. Dental applications case study 6—CAD/CAM/AM applications in the manufacture of dental appliances
5.39.1. Introduction
5.39.2. Material and methods
5.39.3. Results
5.39.4. Discussion
5.39.5. Conclusion
Part 5.6. Research applications
Chapter 5.40. Research applications case study 1—Bone structure models using stereolithography
5.40.1. Introduction
5.40.2. Human sample data
5.40.3. The use of stereolithography in the study of cancellous bone
5.40.4. Single human bone sample (approximately 45-mm cube)
5.40.5. Multiple human samples (approximately 50-mm cube)
5.40.6. Conclusion
Chapter 5.41. Research applications case study 2—Recreating skin texture relief using CAD/AM
5.41.1. Introduction
5.41.2. A definition of skin texture
5.41.3. Identification of suitable technologies
5.41.4. Methods
5.41.5. Case studies
5.41.6. Results
5.41.7. Discussion
5.41.8. Conclusions
Chapter 5.42. Research applications case study 3—Comparison of additive manufacturing materials and human tissues in computed tomography scanning
5.42.1. Introduction
5.42.2. Materials and methods
5.42.3. Results
5.42.4. Discussion
5.42.5. Conclusions
Chapter 5.43. Research applications case study 4—Producing physical models from CT scans of ancient Egyptian mummies
5.43.1. Introduction
5.43.2. Technology
5.43.3. Case studies
5.43.4. Conclusions
Chapter 5.44. Research applications case study 5—Trauma simulation of massive lower limb/pelvic injury
5.44.1. Introduction
5.44.2. Materials and methods
5.44.3. Discussion and conclusions
Chapter 5.45. Research applications case study 6—biomodeling with bio-inspired soft materials
5.45.1. Introduction
5.45.2. A brief history of soft materials in medical modeling
5.45.3. Soft materials for medical modeling
5.45.4. Organic additive manufacturing
5.45.5. Liquid silicone rubber additive manufacturing
5.45.6. Craft-enhanced additive manufacturing
5.45.7. Characterization of analogous materials
5.45.8. PDMS variants
5.45.9. Practical applications
5.45.10. Conclusion
Chapter 5.46. Research applications case study 7—Three-dimensional bone surrogates for assessing cement injection behavior in cancellous bone
5.46.1. Introduction
5.46.2. Methods
5.46.3. Results
5.46.4. Discussion
Chapter 5.47. Research applications case study 8—Full-color medical models—Worked examples
5.47.1. Project background
5.47.2. How the project started
5.47.3. Project vision
5.47.4. Design approach
5.47.5. Impact on the engineering and medical professions
5.47.6. Future work
Chapter 6. Future directions in medical modeling
6.1. Background
6.2. Technological advances
6.3. 4D printing: The next dimension in the healthcare
6.4. Clinical practicality at the point of care
6.5. Medical modeling for all
6.6. Summary
Chapter 7. Glossary and explanatory notes
7.1. Glossary of terms and abbreviations
7.2. Medical explanatory notes
Index

Richard Bibb

Prof Richard Bibb is a Professor of Medical Applications of Design at Loughborough University, UK. He graduated from Brunel University, UK (1995) with a BSc (Hons) in Industrial Design. He then ‎undertook doctoral research in Rapid Prototyping at the National Centre for Product Design and Development Research (PDR), Cardiff Metropolitan University, UK. This study involved the development of a computerised Rapid Prototyping selection system for designers in small companies.

After gaining his PhD in 1999 he established the Medical Applications Group at PDR to conduct collaborative applied research in medical applications of design technologies such as CAD and 3D Printing. He rose to the position of Director of Research ‎for PDR before moving to Loughborough University in 2008.‎ In 2014 he established the Digital Design & Fabrication research lab (DDF) which focuses on ‎advanced computer-aided design (CAD), 3D ‎Printing and Additive Manufacturing technologies.

Professor Bibb's personal research focus is the application of advanced product design and development ‎technologies in medicine, surgery, rehabilitation and assistive technology.

Affiliations and expertise

Professor of Medical Applications of Design School of Design and Creative Arts, Loughborough University, Loughborough, UK

Dominic Eggbeer

Prof Dominic Eggbeer is a Professor of Healthcare Applications of Design at PDR, Cardiff Metropolitan University. His research focuses on the design and development of personalized medical devices, applying his knowledge to surgical implants, facial prosthetics, dental devices and other areas of rehabilitative medicine.

In addition to his academic research, he manages a small, ISO 13485 compliant commercial team in the design of patient specific implants and other devices. Eggbeer also has a leading role in collaboration, dissemination and in supporting broad uptake of novel design engineering approaches in healthcare.

Affiliations and expertise

Professor of Healthcare Applications of Design at PDR, Cardiff Metropolitan University, Wales, UK

Abby Paterson

Dr Abby Paterson is the Programme Director, Design for Additive Manufacturing and Lecturer in Industrial Design and Technology at Loughborough University, UK. She specialises in 3D scanning, CAD, and digital, automated fabrication (CNC milling and Additive Manufacture).

Abby graduated with a BSc in Product Design and Technology and a PhD in 3D Scanning, CAD and Additive Manufacture for Medical Applications from Loughborough University. After completing her PhD, she was appointed as a lecturer at the University of Manchester in the School of Materials; she continued her research in digital design and fabrication for medical devices and then returned to the Loughborough Design School as a lecturer in 2014.

She is currently completing a 12-month industrial fellowship in 3D scanning, CAD and AM, funded by the Royal Academy of Engineering. Abby has also received funding from Arthritis Research UK to develop specialised 3D CAD software for the design of customized 3D-printed wrist splints. In 2015, Abby was awarded a Loughborough University Teaching Innovation Award. Abby also engages with consultancy work through the Loughborough University Enterprises Ltd.

Affiliations and expertise

Programme Director, Design for Additive Manufacturing and Lecturer, Industrial Design and Technology School of Design and Creative Arts Loughborough University, Loughborough, UK

Mazher Iqbal Mohammed

Dr Mazher Iqbal Mohammed is a senior lecturer in digital fabrication, a member of the Digital Design and Fabrication Research Group within the Loughborough University Design School and an Honorary Research Fellow with Deakin University’s School of Medicine.

His qualifications include a combined undergraduate Master’s in physics (MPhys) from the University of Edinburgh and an Engineering Doctorate (EngD) in medical device biotechnology from the University of Strathclyde. Dr Mohammed has worked in academia for over ten years across several institutes both in the UK and Australia, including roles at Heriot Watt University, the Australian National University (ANU) and Deakin University. During this time, he has developed a highly multidisciplinary skill set working at the intersection of design, manufacturing, material sciences, chemistry and biomedical engineering.

Dr Mohammed’s research interests focus on digitally driven fabrication technologies, aimed at positively impacting human development and longevity. He is particularly interested in the intersection of disruptive technologies such as additive manufacturing, design and data driven processes to develop innovative and practical solutions in fields ranging across healthcare, humanitarian technologies, closed-loop sustainable manufacturing and Industry 4.0.

Affiliations and expertise

Senior Lecturer, Digital Fabrication, School of Design and Creative Arts, Loughborough University, Loughborough, UK

Life Sciences

Physical Sciences & Engineering

Social Sciences & Humanities

Health

Medical Modeling

The Application of Advanced Design and Additive Manufacturing Techniques in Medicine

Purchase options

Save 50% on book bundles

Institutional subscription on ScienceDirect

Richard Bibb

Dominic Eggbeer

Abby Paterson

Mazher Iqbal Mohammed