Abstract:
Maxillectomy is the surgical removal or resection of the maxilla or upper jaw bone. A total or partial
maxillectomy can be performed depending on how far the tumour has spread. This paper will discuss a
patient diagnosed with an aggressive tumour in half of the top jaw who had to undergo an operation to
remove the hemi-maxilla and orbital floor. Due to the extent and complexity of the defect, it was decided
to manufacture an anatomical model of the hard tissues for planning a possible laser-sintered titanium
implant using Additive Manufacturing (AM). The CRPM had only two weeks to design and manufacture
the titanium implant, due to the severity of the tumour. The anatomical model was sent to the surgeon to
cut the nylon model where the bone resection was planned. Furthermore, the prosthodontist made a wax
model of the planned titanium frame that was reverse- engineered and used as reference geometry in
the design software.Materialise® design suite was used to design the patient-specific maxilla and cutting
jig. The EOS M280 Direct Metal Laser Sintering (DMLS) system was instrumental in achieving the direct
manufacturing of the bio-compatible titanium implant. The EOS P385 system was used to manufacture
the pre-operation planning model as well as the cutting jig.The process chain followed to complete this
case study will be discussed showing how this intervention improved the quality of life of a SA patient.
Furthermore, the proposed paper and presentation will discuss the post-operation review of the patient
showing the impact AM had in accelerating patient-specific implant manufacturing. The authors seek to
claim a progressed level of maturity in the proposed manufacturing value chain. The claim is based on
the successful completion of the analysis and synthesis of the problem , the validated proof-of-concept of
the manufacturing process and the in-vivo implementation of the final product.
