Development of prototyped molds for cranioplasty using desktop 3D printers: A single-center experience

Cranioplasty is one of the most commonly performed neurosurgical procedures worldwide. When an autologous bone fragment is unavailable, reconstruction is often carried out using biocompatible materials such as polymethylmethacrylate (PMMA). 3D printing has emerged as an effective alternative, enabling the creation of molds for shaping PMMA implants during surgery. However, the high cost of outsourced molds has prompted the exploration of desktop 3D printers as a viable, low-cost solution. This study demonstrates the additive manufacturing process of molds for cranioplasty using desktop 3D printers. Computed tomography images were processed with specialized software to create two mold components, which were subsequently manufactured using 3D printers. The molds were utilized for implant fabrication in 35 surgeries. Of the 35 cranioplasties, 7 patients (20%) required reoperation due to epidural empyema (1), brain abscess (1), serosanguinous rhinorrhea (1), implant defect (1), and suture dehiscence (3). Plate removal was needed in only 4 cases (11.43%). The average mold cost, including segmentation, modeling, slicing, printing, and post-processing, was $100.00. All molds were successfully used. The results indicate that the use of 3D-printed molds is a feasible, accessible, and safe approach, yielding favorable clinical and aesthetic outcomes, with a complication rate consistent with the literature. This research emphasizes the importance of collaboration between neurosurgeons and 3D printing specialists, suggesting that effective communication between teams is crucial for optimizing the use of this technology. • Desktop 3D printers produce personalized molds for PMMA implants in surgery. • High satisfaction with aesthetic outcomes and clinical results in 35 surgeries. • 3D-printed molds enable efficient, low-cost cranioplasty with minimal complications. • Collaboration between neurosurgeons and 3D experts crucial for successful outcomes.