Custom 3D-Printed Supports for Intraoperative Positioning in Endocrine Surgery: A Technical Report

BackgroundCustomizable positioning devices for endocrine surgery are scarce, and existing solutions often rely on improvised supports. This technical report introduces 3 patented 3D-printed devices developed to enhance precision, ergonomics, and safety during endocrine procedures.Methodology and Device DescriptionThe required devices were designed using available software and printed via Fused Deposition Modeling with ABS filament. Post-processing involved acetone smoothing and the addition of an EVA lining for enhanced patient comfort. Specifically, a 3D-printed neck pillow and arm sling were applied during thyroidectomy, while a 3D-printed prone mattress was utilized for adrenalectomy. These devices incorporated modular cushions and magnetic fasteners to facilitate rapid assembly.Preliminary ResultsThe thyroid surgery yielded optimal neck extension, a 73-minute operative time, and 50 mL blood loss without complication. Adrenal surgery was completed with a 105-minute operative time and 50 mL of blood loss, followed by an uneventful recovery. Both patients were discharged on postoperative day 2. The surgical devices allowed stable intraoperative positioning in the reported cases, without observed positioning-related adverse events.Current StatusThese lightweight, modular 3D-printed devices were designed to support ergonomic and stable positioning in endocrine procedures. Despite their preliminary success, broader adoption will require addressing challenges related to cost, regulation, and process integration.