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A CAD and AM process for maxillofacial prostheses bar-clip retention

Steffan Daniel (National Centre for Product Design & Development Research (PDR), Cardiff Metropolitan University, Cardiff, UK)
Dominic Eggbeer (PDR – International Centre for Design & Research, Cardiff Metropolitan University, Cardiff, UK)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 18 January 2016

348

Abstract

Purpose

This paper aims to present novel techniques for designing maxillofacial prostheses using computer-aided design (CAD) and additive manufacture (AM), focusing on the integration of osseointegrated retention components. A fully computer-aided approach is considered as a major step towards reducing patient consultation time and an efficient workflow.

Design/methodology/approach

The workflow was illustrated through a phantom model. 3D laser scanning was used to capture the phantom anatomy and pre-fabricated geometric features, which enabled the implant positions to be precisely reverse engineered in the data. A novel CAD workflow was used to design the retention mechanisms and a mould. The individual components were fabricated using AM. A definitive silicone prosthesis that incorporated a bar/clip retention mechanism was then fabricated.

Findings

The research demonstrated that retention components can be integrated into prostheses using appropriate CAD and AM technologies.

Originality/value

This study demonstrates the feasibility of a computer-aided workflow for designing facial prostheses that incorporate osseointegrated retention mechanisms. Novel techniques were developed to: digitise abutment details using custom scanning locators; design retention components; manufacture retention components using AM; integrate retention components into a CAD and AM prosthesis mould. This overcomes limitations identified in previously published cases and demonstrated significant potential to reduce patient consultation time and create a clinically viable process.

Keywords

Acknowledgements

The authors thank Matt Parkes, Dave Cruickshank and Dave Beeby at Renishaw Plc (UK) for fabricating the sample bar structure used in the development of the process. They also thank Peter Evans and Kelly Morris at Morriston Hospital for moulding the ear prosthesis in silicone and advising on lab techniques for conventional prosthesis production.

Citation

Daniel, S. and Eggbeer, D. (2016), "A CAD and AM process for maxillofacial prostheses bar-clip retention", Rapid Prototyping Journal, Vol. 22 No. 1, pp. 170-177. https://doi.org/10.1108/RPJ-03-2014-0036

Publisher

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Emerald Group Publishing Limited

Copyright © 2016, Emerald Group Publishing Limited

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