Replicating Healthy and Metastatic Behavior: A Biomechanical Investigation Using 3D Printed Vertebrae Models

Understanding the biomechanical impact of metastatic involvement in the spine is critical for patient care and treatment planning. However, limited access to human specimens and ethical concerns hinder research in this field. In this study, we propose a novel approach using multi-material 3D printing to create patient-specific synthetic vertebrae models for investigating metastatic involvement. A pipeline was designed, tested and compared, utilizing quantitative Computer Tomography (qCT) data for model generation. Mechanical properties of healthy and metastatic vertebrae models were evaluated through compression testing. Results showed that qCT-derived models closely mirrored ex-vivo data, demonstrating comparable failure loads and fracture modes. Furthermore, the use of hyperelastic flexible material for simulating metastasis proved effective in replicating failure mechanisms. This innovative approach offers a cost-effective and ethical alternative for studying spinal metastases, with the potential to enhance treatment strategies and patient outcomes.