Craniomaxillofacial Surgical Planning

3D Systems' VSP® surgical planning solutions for craniomaxillofacial (CMF) applications received FDA clearance as a service-based approach to personalized surgery over 10 years ago.

3D Systems and Stryker Corporation have partnered to provide surgeons with best-in-class products and services for craniomaxillofacial surgeries. As a leader in personalized healthcare solutions, 3D Systems has planned and delivered devices for more than 140,000 patient-specific cases. The Stryker Craniomaxillofacial business specializes in providing patient-specific options and innovative solutions that help drive efficiencies in surgical suites. The combination of Stryker’s specialized team and advanced implants with 3D Systems' cutting-edge 3D printing technologies and expert consulting services positions both companies to provide a superior level of service to healthcare professionals who use these revolutionary solutions.

More about VSP Guide Options >>
Virtual Surgical Planning Workflow with 3D Systems and Stryker

FDA clears first 3D-printed PEEK cranial implant

Discover the VSP® PEEK Cranial Implant. This patient-specific solution offers a precise fit and reliable performance for cranioplasty procedures to restore defects in the skull. See how the EXT 220 MED enabled this innovation.

Craniomaxillofacial Applications

VSP Orthognathics
VSP Reconstruction
VSP Cranial
VSP Distraction
VSP Trauma
Jaw in a Day

VSP Orthognathics

This complete planning service eliminates the need for traditional model surgery. The first step is an interactive web meeting between the surgeon and an engineer where they simulate the procedure, including surgically accurate placement of osteotomies and bony movements. The result is an intermediate and final splint providing the clinical transfer of the digital plan into surgery. Splints are designed with several customizable features, such as minimizing/maximizing occlusal overlap, palatal strutting, sandwich splints, and more. Final surgical splints are produced in a clear material approved for up to 30 days of intraoral use. Additional patient-specific surgical guides can also be produced as required.

Features and Technical Requirements
vsp orthognathics positioning iso

VSP Orthognathics solution provides a variety of guide options

VSP Reconstruction

This surgical planning solution is intended for head and neck reconstruction. The most widely used application is for mandibular or maxillary reconstruction using the fibula free flap and other vascularized grafts. It can also be used for reconstruction techniques for trauma, congenital defects or tumors of the facial skeleton. Surgeons report that use of the VSP Reconstruction solution enables them to perform these surgeries with more confidence and a three-dimensional perspective as compared to cases without pre-surgical planning. Dozens of peer reviewed journal articles substantiate the use of the VSP Reconstruction models, guides, and templates to reduce surgical time and create more accurate reconstructions.

Benefits and Deliverables
Demo of 3D print rendering of a jaw reconstruction

VSP Reconstruction mandible model with pre-planned cut lines

VSP Cranial

This solution applies proven and FDA-cleared virtual surgical planning techniques to craniofacial cases, especially procedures related to craniosynostosis and cases that require cranial vault distraction. Building on the success of the renowned VSP surgical planning solutions, VSP Cranial delivers improved surgical outcomes to surgeons by providing accurate pre-surgical visualization of cuts and movements, real-time comparison to age-matched normative anatomical contour, and personalized marking and positioning guides for realization of a digital plan.

VSP Cranial Features
VSP Cranial Pre-Op Resected with Guides

VSP Cranial provides advanced visualization for pre-surgical planning

VSP Distraction

 

These surgical planning solutions for distraction osteogenesis include designing placement of osteotomies, planning of distractor vectors and creation of templates for guidance of device placement, device bending and osteotomy placement. The patient’s 3D anatomy is reviewed during the planning session, and underlying teeth roots and nerves are visualized for proper distractor placement. Each case is customized to the actual distractor file to be used during surgery. Some uses of VSP Distraction include osteotomy placement, identifying a distraction vector plan, creation of templates to guide device placement, and facilitation of pre-operative hardware set up.

Uses for VSP Distraction
VSP Distraction anatomic models with guides

VSP Distraction enables osteotomy planning

VSP Trauma

This solution allows the surgeon to digitally reduce the fractured bony segments prior to surgery. The digitally reduced plan is transferred to the operating room through a series of models, guides, templates, or digital images. Since these are typically time-sensitive cases, 3D Systems makes quick service a priority. Deliverables for VSP Trauma cases include patient-specific osteotomy and positioning guides, occlusal-based positioning splints, and digitally reduced, perfected or mirrored anatomic models. Modified DICOM can be produced based on the surgical plan for use in intraoperative stereotactic navigation systems.

VSP Trauma Deliverables
a skull rendering for VSP Distraction

Facilitating trauma reduction surgery with repositioning guides

Jaw in a Day

Jaw in a Day® enables immediate placement of a provisional dental prosthesis during a single-stage free tissue transfer jaw reconstruction surgery. The surgical planning, along with guide and prosthesis designs, is completed using state-of-the-art CAD/CAM technology, allowing the patient to emerge after a single surgery with a full jaw reconstruction, including dental rehabilitation.

* Jaw in a Day is a registered trademark of David L Hirsch. 

Technical Requirements and Considerations
MandibleISO IJaw

Jaw in a Day allows for immediate placement of a provisional dental prosthesis

  • VSP Guide Options

    3D Systems is always innovating its products and services to address the needs of surgeons performing maxillofacial and reconstructive surgeries. 3D Systems’ surgical guide options offer unprecedented flexibility in design and are capable of having lower profile designs to enhance visibility and access in the surgical site, while also possessing improved strength and rigidity.

  • LeFort - Exploded View

    Hybrid Guides

    Multi-material benefits: Low profile, easy guide placement, and more

    The latest enhancement to the surgical planning solutions portfolio, VSP Hybrid Guides provide you with occlusal registration from a nylon guide for accurate placement plus the increased strength and rigidity1 of a titanium cutting and drilling guide. These guides are assembled with easy-to-use connection sites that are engineered to confirm a proper connection. Depending on your preference, patient-specific instruments can be designed that allow multiple cutting and drilling locations on a single occlusal-based guide.

     

  • a CMF model

    Titanium Guides

    Material made 20x stronger1; enables customization, increased visualization, lower profile

    With titanium, you can experience increased strength over our traditional guides, allowing cutting and drilling directly through the guides. Maximize functionality of the guides by altering cut slots to match your surgical blade. Choose the height of your drill guide and cutting slots to control trajectory or reduce guide profile height. With slimmer profiles, the guides can provide easier placement in areas with limited exposure plus increased visibility with the new cellular structure.

  • 3D printed nylon guides for VSP CMF

    Nylon Guides

    Material made 88% tougher1, customized by you, for you.

    Nylon guides can better withstand mechanical forces, providing an improved performance. Select occlusal or bone-borne guides to fit your surgical needs. Further customize the guides with optional features such as nasal floor registration. Slimmer profile guides can provide easier placement in areas with limited exposure. Improve your visibility of the surgical site with lower profiles and a new cellular structure design which can help you better see anatomy. 

  • 3D Printed VSP CMF SLA fibula guide

    Photopolymer

    Proven since the start, the original guide.

    Used in thousands of cases, our traditional guide helped create the personalized medicine approach. Designed from the VSP session, these surgical guides are the physical output of the pre-planned surgery. They can assist you with patient-specific marking, positioning, and osteotomy decisions in the OR. 

  • References:

    1: Data compared to 3D Systems’ Traditional cutting and marking guides. Proprietary mechanical validation testing data on file at 3D Systems. 

VSP End-to-End Workflow in Action

Integrating precision healthcare with 3D technologies for better surgical outcomes

  • an icon representing a skull

    Digitize

    Process patient-specific medical data into a digital 3D model

  • an icon representing simulation of a skull

    Plan

    Schedule online surgical planning meeting between surgeon and 3D Systems biomedical engineer

  • an icon representing a scanned design

    Design

    Create patient-specific 3D models, guides and templates

  • an icon representing manufacturing

    Manufacture

    3D print models and guides to smoothly transition surgical plan into operating room

  • an icon representing a microscope and inspection

    Inspect

    Put models through 3D Systems’ intensive quality control system

  • an icon representing delivery with two hands shaking

    Deliver

    Transfer virtual plan to the operating room with patient-specific models and guides

Download the VSP Infographic

  • Complete an Order

    Uploading your files to begin a case is an easy 2 step process. Step 1, upload medical imaging data by clicking on the link below. Step 2, download and complete the order form and email it to [email protected]. Having trouble? Contact our support team via email [email protected] or call our offices for assistance +1 720 643 1001. 

Products used for CMF

EXT 220 MED 3D Printer

EXT 220 MED

The only extrusion platform that features an integrated clean room and is validated by leading medical device manufacturers and hospitals worldwide.

SLS 380 3D printer

SLS 380

Industrial-scale, process controlled additive manufacturing solution for selective laser sintering

DMP Flex 350 Duel 3D printer

DMP Flex 350, DMP Flex 350 Dual and DMP Flex 350 Triple

Robust, flexible metal 3D printer for rapid part production

D2P hero banner

DICOM to Print

Advanced Visualization Software

Freeform

Organic 3D Design Software

3D Systems 3DXpert hero image

3DXpert

All-in-One Integrated Software for Industrial Additive Manufacturing

Accura ClearVue (SLA)

High clarity plastic, multitude of applications

Accura ABS White (SL 7810) (SLA)

Simulate and replace CNC-machined white ABS parts

LaserForm 17-4PH (A)

Excellent corrosion resistance, high strength with good toughness

LaserForm Ti Gr23 (A)

High strength, low weight, excellent biocompatibility - lower Oxygen than Gr5

LaserForm Ti Gr1 (A)

Light weight, biocompatible, extreme temperature and corrosion resistance

DuraForm PA

Durable polyamide (nylon) material for production parts

Talk to and Expert about CMF Solutions

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