Investigation of the Effectiveness of Cranial Helmets Produced With 3D Printing Technology in Positional Cranial Deformities

INTRODUCTION: Positional cranial deformity (PCD) is a common cranial asymmetry observed in infants and is primarily associated with prolonged external pressure on the developing skull. Cranial helmet therapy is widely used for the correction of these deformities. Recent advances in 3-dimensional (3D) technologies have enabled the production of custom cranial helmets through digital scanning and 3D printing, potentially improving anatomic fit and production efficiency. This study aimed to evaluate the effectiveness of custom-made cranial helmets produced using 3D scanning and 3D printing technologies in infants with positional cranial deformities. METHODS: This prospective pilot study included 9 infants aged 4 to 9 months diagnosed with positional cranial deformity and 9 healthy infants of similar age as controls. Custom cranial helmets were produced using 3D scanning and 3D printing technologies. Infants in the treatment group used the helmets for an average of 5.2 months. Cranial asymmetry indicators-cranial vault asymmetry (CVA), cranial vault asymmetry index (CVAI), and cephalic index (CI)-were measured at regular follow-up intervals. Statistical analyses were performed using IBM SPSS Statistics 25.0 software. RESULTS: Helmet therapy resulted in significant improvements in cranial symmetry. At the end of treatment, CVA and CVAI values showed statistically significant decreases (P<0.05), while CI values demonstrated a smaller but still significant reduction. No significant difference was observed between the case and control groups in head circumference growth rates, indicating that helmet therapy did not negatively affect cranial growth. CONCLUSION: The findings suggest that custom cranial helmets produced using 3D scanning and 3D printing technologies may provide an effective and safe treatment option for infants with positional cranial deformities. Early initiation of treatment and higher initial deformity severity were associated with greater therapeutic improvement. These results support the potential clinical utility of 3D-printed cranial helmets as a modern and patient-specific approach in the management of positional cranial deformities.