In the fast-paced world of surgery, time is often of the essence. Every moment saved in pre-operative planning can lead to improved patient outcomes. Traditionally, surgeons have relied on radiological imaging such as CT or MRI scans to plan complex surgeries. While these images offer valuable insights, they are two-dimensional, leaving room for interpretation. In contrast, 3D printed models provide a tangible, precise representation of a patient’s anatomy, enabling better surgical planning, shorter surgery times, and improved outcomes.

A model of a patient with destroyed bone in the forehead about to undergo reconstructive surgery

The Benefits of Faster 3D Printed Models

The game-changer here is how quickly these 3D printed surgical models can now be produced. Thanks to automated 3D printing services, surgeons can receive patient-specific models within hours—significantly faster than the days or weeks typically required by traditional methods.

Let’s explore how this breakthrough is impacting surgical outcomes.

Faster Production, Better Outcomes

Automated 3D printing has drastically cut the time needed to produce surgical reference models. However, the power of this technology goes beyond speed—it's the precision that sets it apart. Studies show that 3D printed models significantly improve surgical accuracy when compared to relying solely on radiological images.

1. Enhanced Surgical Precision

A systematic review of 3D printed models used in cranio-maxillofacial surgeries showed that surgeons achieved greater precision and made better intraoperative decisions with these models. Physical 3D models allow surgeons to visualize patient-specific anatomy, enhancing planning accuracy and reducing errors​​(BioMed Central).

A study published in The Journal of Oral and Maxillofacial Surgery confirmed these findings, showing that 3D printed models improved surgeons' ability to plan and execute complex craniofacial procedures, reducing complications during surgery​​(Oxford Academic).

A set of jaws with severe bone destructions due to tumour growth

2. Reduced Operating Times

One of the most immediate benefits of 3D printed surgical models is the reduction in surgery time. For example, a study in The Lancet found that surgeons using 3D printed models for cardiac surgeries significantly reduced operating times. By allowing surgeons to pre-plan complex operations, these models lowered the risk of complications, such as infections or blood loss, which in turn improved overall patient outcomes​​(BioMed Central).

In orthopedic surgeries, custom 3D printed implants have also been shown to reduce procedure times by enabling surgeons to create implants that perfectly match each patient’s anatomy​​(The Open Dentistry Journal). This familiarity with the model before surgery enhances efficiency and reduces the potential for errors during the operation.

3. Improved Pre-operative Planning

Perhaps the most significant advantage of 3D printed models is their ability to improve pre-operative planning. By offering a three-dimensional, physical replica of a patient’s anatomy, these models enable surgeons to simulate and practice procedures before the actual operation. This is especially beneficial for complex cases.

A 2020 study published in The Journal of Orthopaedic Surgery and Research found that orthopedic surgeons using 3D printed models for complex joint replacements saw improved surgical outcomes due to enhanced planning and practice, reducing the likelihood of errors​​( SpringerLink).

Applications Across Various Surgical Fields

The advantages of 3D printed models span multiple medical specialties:

• Cranio-maxillofacial surgery: Surgeons report improved outcomes and fewer complications when using 3D printed models for complex reconstructions and trauma surgeries​​(BioMed Central)​(Oxford Academic).
• Orthopedic surgery: Custom implants designed using 3D models result in better implant fit, shorter surgery times, and improved recovery rates for patients​​(The Open Dentistry Journal).
• Cardiac surgery: Pre-operative 3D models allow surgeons to rehearse complex procedures, reducing surgery time and improving outcomes​​(BioMed Central).

Improved Patient Communication and Understanding

It’s not just surgeons who benefit from 3D printed models—patients also gain a clearer understanding of their condition and the proposed surgical plan. A 2019 study in PLOS ONE found that patients who were shown 3D printed models of their anatomy reported lower anxiety and a better understanding of their surgical procedures than those shown only radiological images. This improved communication fosters better patient compliance and ultimately leads to better outcomes​​(BioMed Central).

A children's cranium where the teeth didn't grow as they were supposed to was used to describe the procedure to the parents before surgery and for the surgeon to see the exact anatomy of the child before cutting. 

From Days to Hours: The Power of Automated 3D Printing

What sets automated 3D printing apart is not only its precision but also its speed. Traditional methods for creating surgical models can take days or even weeks, but with automated 3D printing services, like those offered by RapAdd MFG, patient-specific models can now be quoted, manufactured and delivered in mere hours, 7 days a week. This rapid turnaround time is essential in urgent or complex cases where every minute counts.

At RapAdd MFG, we offer high-quality, sterilizable 3D printed surgical models tailored to your patients’ specific needs. Our automated service can quote, produce, and deliver these models in hours—helping you improve surgical precision, reduce surgery times, and enhance patient care.

Conclusion

The combination of faster production and enhanced precision provided by 3D printed models is revolutionizing surgical planning. From reducing operating times to improving patient communication, the benefits are clear: 3D printed models are setting a new standard in modern medicine.

Interested in learning more about how automated 3D printing can enhance your surgical practice? Contact us today to discover how we can deliver customized models to you in hours, not days.