A Study of 3D Printing Technology in the Fabrication and Clinical Application of Titanium Mesh Shaping Molds for Cranial Bone Repairs

Objective: Explore a clinical-led approach that applies digital 3-dimensional (3D) reconstruction technology to titanium mesh design and production to achieve more cost-effective and personalized skull repair goals. Materials and Methods: To develop a clinician-led titanium mesh fabrication method, which is achieved by digitally 3D reconstructing the patient’s own medical imaging data and designing a personalized mold for cranial defects, physically constructing the mold using 3D printing technology, and ultimately shaping the titanium mesh according to the patient’s personalized mold by an experienced clinician. A total of 60 cases of adult patients with cranial defects who met the inclusion criteria of this study and were seen in the Department of Neurosurgery from January 2022 to January 2024 were collected for retrospective analysis. Results: A total of 30 cases of cranial defect molds and personalized repair titanium mesh were made by 3D printing technology. All the molds and personalized repair titanium mesh were successfully produced, and all the titanium mesh matched with the molds, and the time consumed for the production of titanium mesh in group A was less than that in group B, with a statistically significant difference ( P <0.001), and the cost of production of titanium mesh in group A was more economically advantageous than that in group B ( P =0.002). Conclusion: The approach of titanium mesh designed and fabricated autonomously by clinicians in conjunction with 3D printing technology is less time-consuming, more economical, and highly personalized.