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Fabrication of Patient Specific Genioplasty Surgical Template Using Investment Casting

Santosh Kumar Malyala, Ravi Kumar Y, Rakesh Kumar and Chitra Chakravarthy

Additive Manufacturing (AM) is one of the best techniques to fabricate customized medical models. This technique best suited for the medical industry. The surgical template design and dimensions vary from patient to patient, depending on the anatomy of the patient. AM provides flexibility to design a patient specific surgical template using the patient CT scan data. Medical processing software converts DICOM to 3D CAD data. This 3D CAD data is used to design the patient specific surgical template. This surgical template data is then converted into an STL file format to fabricate medical models using AM machines. The initial surgical template is fabricated using FDM machines, which are easily available and this template is used for pre surgical planning. After satisfactory results are obtained in the pre surgical planning, the same STL file is fabricated using a castable resin. The castable resin model is used for preparation of the mould for casting process. This mould is then used to produce the final surgical template with medical grade SS316. The cost of the final metal surgical template is reduced by 30 percent compared to production of same model fabricated using metal AM system. The major advantage of this process is that we obtain a patient specific template in traditional approved way, but at reduced cost.