Role of Stereolithographic Models in Pre-operative Planning of Complex Maxillofacial Surgical Procedures: A Comprehensive Review

AbstractThe increasing complexity of maxillofacial surgical procedures has necessitated the development of advanced pre-operative planning tools that improve surgical accuracy and clinical outcomes. Stereolithographic (SLA) models, generated from high-resolution imaging data using three-dimensional (3D) printing technology, have emerged as valuable adjuncts in oral and maxillofacial surgery. These patient-specific anatomical replicas provide enhanced visualization of complex craniofacial structures, facilitate surgical simulation, and support the fabrication of customized surgical guides and implants. This review comprehensively examines the role of stereolithographic models in the pre-operative planning of complex maxillofacial surgical procedures. A narrative review of the literature was conducted using electronic databases including PubMed, Scopus, and Google Scholar, focusing on studies evaluating the clinical applications, accuracy, and effectiveness of SLA models in oral and maxillofacial surgery.Evidence from the literature demonstrates that stereolithographic models improve anatomical understanding, enable precise surgical planning, reduce intraoperative uncertainty, and enhance communication among multidisciplinary teams. Their applications have been widely reported in craniofacial reconstruction, orthognathic surgery, maxillofacial trauma management, dental implantology, temporomandibular joint surgery, and oncologic reconstruction. Several studies have also reported reductions in operative time and improved reconstruction accuracy through preoperative simulation and customization of surgical hardware. Despite limitations related to production cost, fabrication time, and inability to replicate soft-tissue dynamics, ongoing advancements in computer-aided design/computer-aided manufacturing (CAD/CAM), artificial intelligence, virtual surgical planning, and additive manufacturing technologies continue to expand their clinical utility. Stereolithographic models represent a significant advancement in personalized surgical planning and are expected to become an integral component of contemporary maxillofacial surgical practice, contributing to improved precision, predictability, and patient outcomes.