Clinical Feasibility and Surgical Outcomes of a 3D-Printed Template-Based PMMA Implant Workflow for Genioplasty

Background: Achieving facial harmony in patients with micrognathia requires precise chin augmentation. While conventional ready-made implants often fail to conform to unique mandibular surfaces, expensive patient-specific options like PEEK or Titanium lack intraoperative adjustability. We introduce an innovative, cost-effective workflow utilizing 3D-printed templates to fabricate customized Polymethyl Methacrylate (PMMA) implants, emphasizing their clinical feasibility and intraoperative versatility. Methods: We retrospectively analyzed 20 patients with mild-to-moderate micrognathia (<6 mm advancement) who underwent genioplasty between March 2021 and June 2022. Patient-specific templates were produced via Fused Deposition Modeling (FDM) using low-shrinkage Acrylonitrile Butadiene Styrene (ABS) filament. During surgery, final PMMA implants were molded using these sterilized templates. Accuracy was evaluated by comparing mental advancement across preoperative, virtual simulation, and 6-month postoperative stages using Vectra 3D scanning. Results: Quantitative analysis revealed high fidelity between virtual planning and clinical outcomes. The mean discrepancy in horizontal advancement was only 1.02 mm (Planned: 5.04 mm vs. Actual: 4.02 mm). Statistical analysis showed a strong positive correlation (r = 0.928, p = 0.001). Subjective patient satisfaction was high, with 90% reporting “exceptional” or “very improved” results on the Global Aesthetic Improvement Scale (GAIS). Two cases of transient numbness resolved spontaneously within two months. Conclusions: This workflow combines FDM-based template fabrication with intraoperative PMMA molding, enabling real-time adjustment of implant geometry. The results demonstrate a high level of agreement between virtual planning and postoperative outcomes, supporting the clinical reliability of this approach. It may serve as a practical alternative to conventional CAD/CAM methods, particularly in cases requiring both precision and intraoperative flexibility.