A novel 3D-printed noninvasive immobilizer for head stability during surgery of the orbit and skull base

This study investigates a 3D printed, noninvasive headrest that was designed for use in orbital and skull base surgeries and compares the stability of this innovative headrest to conventional head immobilization devices using accelerometer-based measurements. A 3D model of a headrest was developed using two plastic materials: polyethylene terephthalate glycol (PETG) and thermoplastic polyurethane (TPU). Stability, in g-force, was measured for these headrests, Gel Head Donut Adult Blue Diamond®, and a no headrest condition. A non-embalmed cadaver’s head was placed in each headrest condition and subjected to controlled oscillations using Bellco Glass’ Orbital Shaker. Acceleration data were recorded over a 3-second interval. The average acceleration, measured in g-force (g), over 3 s for each headrest configuration was: (1) no headrest: 0.068116 g ± 0.058498, (2) Gel Donut head immobilizer: 0.064223 g ± 0.027463, (3) PETG headrest: 0.053331 g ± 0.037782, and (4) TPU headrest: 0.056254 g ± 0.032200. The PETG headrest showed a 21.71% improvement over no headrest and a 16.96% improvement over the gel donut headrest in maintaining head stability. And the TPU headrest showed a 17.41% improvement over no headrest and a 12.41% improvement over the gel donut headrest in maintaining head stability. The PETG and TPU headrest provided greater stability compared to the commonly used Gel Head Donut headrest and in the absence of a headrest. This study suggests that the design of this headrest offers a potential noninvasive head stability device, regardless of material composition, that may improve the safety and efficacy of orbital and skull base surgery.