Next-Day 3D Printed Acetabular Fracture Models Enable Pre-Bent Plate Surgery

Overview

This study demonstrates the feasibility of a semiautomatic, in-house 3D printing workflow to produce anatomically accurate acetabular fracture models within 24 hours. These models facilitated pre-bending of reconstruction plates, reducing intraoperative bending time and potentially improving surgical outcomes over a one-year follow-up.

Background

Acetabular fractures present complex 3D fracture patterns requiring precise surgical planning and implant fitting. Traditional 3D printing methods for fracture models are often labor-intensive and time-consuming, limiting their use in urgent trauma care. Existing approaches either lack fracture line detail or require expensive software and external suppliers, impeding routine clinical application. This study aimed to develop a rapid, cost-effective, semiautomatic method to generate printable fracture models suitable for next-day surgery.

Data Highlights

Key Findings

• Semiautomatic segmentation and model generation from CT DICOM data was feasible within clinical time constraints.
• 3D printed models accurately represented fracture anatomy with clearly separated fragments allowing fracture reduction simulation.
• Pre-bending of steel reconstruction plates on the models was possible and plates were sterilized for next-day surgery use.
• Use of the models reduced intraoperative plate bending time and improved implant fit.
• Clinical parameters such as operation time and blood loss were favorably impacted, with positive one-year clinical outcomes.
• The workflow utilized open-source software and low-cost FDM printing, enabling in-house production without prohibitive costs.

Clinical Implications

This rapid, semiautomatic 3D printing workflow enables orthopedic trauma teams to produce patient-specific acetabular fracture models within 24 hours, facilitating preoperative planning and implant preparation. The approach reduces intraoperative time and may improve surgical precision and outcomes. Adoption of open-source software and accessible printing technology supports routine clinical implementation without significant resource burden.

Conclusion

The study validates a practical, efficient method for next-day 3D printed acetabular fracture models that support pre-bent plate surgery, demonstrating clinical feasibility and beneficial outcomes. This approach bridges the gap between advanced 3D printing technology and urgent orthopedic trauma care.

References

1. Brown et al. 2018 -- Early studies of 3D printing in acetabular fracture surgery
2. 3D Slicer Project -- Open-source software for medical image computing
3. Materialise Mimics Innovation Suite -- Commercial 3D medical image processing software