PEEK-Barium sulfate composite for three-dimensional virtual reconstruction of a printed human in vitro model using CT

Purpose The purpose of this study is to test the concept of a relatively low cost but biocompatible customized surgical guide printing method using a new composite material for the FDM process to support accurate virtual model reconstruction in CT. Design/methodology/approach Current additive manufacturing printed surgical guides have problems of scanning artifacts or low computed tomography (CT) values for virtual model reconstruction in CT-assisted surgical operations. These tools always face difficulties in precise positioning due to the effect of human soft tissues and manually made unstable landmarks. To solve this problem, this paper proposes a modified material, polyetheretherketone powder mixed with barium sulfate powder, for printing customized surgical guides with relatively low cost to support a synchronized scanning strategy, for the accurate reconstruction of human tissues and in vitro models. Findings A set of benchmarking experiments and clinical simulation cases were conducted. The results showed that the proposed solution can be used to print surgical guides to form stable and clear CT graphs for three-dimensional digital model reconstruction. Human tissues and in vitro models can be accurately reconstructed using clear CT graphs without any scanning artifacts or difficulties in image segmentation for virtual model reconstruction, thus facilitating accurate operation guidance and positioning. Originality/value This method has wide application potential for printing modular or customized surgical guides with low cost and reusability, especially for surgical operations using CT-assisted navigation systems in underdeveloped regions where medical device costs are a critical issue.