Surgical Model Manufacturing Services

We can manufacture models of most structures which are of interest to surgeons. These are made directly from 3D surfaces which may be derived from CT, MRI or Ultrasound using our own 3d imaging system. We use a computer-controlled milling process to manufacture models from blocks of polyurethane foam. The usual application is in complex bony formations (from CT), for which these models are found to be extremely useful when complex fractures are being surgically repaired.
These models are made in house, and can be prepared quickly if required. We can also make models using stereolithography (using an outside service) if required, but this method is currently rather more expensive.

An intermediate cost alternative is fused deposition modelling. We now have our own Stratasys FDM 3000 system and can manufacture high quality models in ABS plastic in house. This will considerably shorten the time between receiving patient data and having a model ready.

We are able to accept 3D images in a variety of data formats, from different scanners, on different media, including the Internet. The completed models can then be mailed direct to the customer if required.

The first ABS model made on our new FDM 3000 rapid prototyper. Slippage of stent graft after endoluminal abdominal aneurysm repair: note single right renal artery with branch. (more images & movie here)	This is an early example of the use of rapid prototyping . A polyurethane foam model milled directly on our CNC milling machine in 1990.This image also shows theTitanium cranioplasty plate custom made to repair the defect.	An ABS model of an ear used for prosthesis design and manufacture
An ABS model of a mandible	Another early example of the clinical use of RP. This plaster model was made in 1991 by milling two negative mould parts in polyurethane foam and filling the mould with plaster of paris. It shows a compressive fracture of the top of the tibia (knee-joint). This model was a valuable aid at surgery.

Other Applications:

Malar augmentation	Mandibular repair	Orbital Floor repair	Surface scan model	Complex fracture analysis	Fetal heart model

For more information please email Robin Richards, robin@medphys.ucl.ac.uk