Improved Generation-Specific Airway Patency in 3D Printed Models through Layer and Exposure Time Modifications

Three-dimensional (3D) printing offers transformative potential for interventional pulmonology by enabling patient-specific models for simulation, surgical planning, and device development. However, accurate reproduction of the multi-generational airway tree remains limited by printing artifacts and lumen distortion, particularly in resin-based methods. This pilot study evaluated whether modifying resin printing parameters could improve airway patency and anatomical fidelity. Twenty identical human airway models were fabricated with an Elegoo Saturn 8K printer: ten with default manufacturer settings and ten with a modified protocol incorporating reduced layer height, fewer bottom layers, shortened standard exposure time, and prolonged bottom-layer exposure. Bronchoscopic inspection revealed that default settings produced incomplete carinas and collapsed second- and third-generation bronchi, whereas the modified protocol yielded smoother lumens, sharply defined carinas, and continuous branching to third-generation airways. Quantitative scoring confirmed reduced surface artifacts and greater branch continuity in the modified group. These findings demonstrate that tailored resin printing parameters enhance fidelity and functional utility of airway models. Such improvements support applications in high-fidelity training, preoperative planning, patient-specific device design, and computational studies. Parameter optimization may expand the translational role of 3D printing in pulmonary medicine by ensuring models are not only visually accurate but also dynamically functional.