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Foot and Ankle Deformity Reconstruction Using Computer-Aided Design Software and 3D Printing Technology

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Arthrogryposis multiplex congenital (AMC) is a congenital condition characterized by joint contractures and often results in foot and ankle deformities. Due to the abnormal complexity of this case study, a traditional surgical method may not have been feasible. Materialise Mimics Software (Materialise, Belgium) was used to segment the lower limb. Reverse-engineering using SolidWorks Software (Dassault Systems, France) was used to visualize the bone intersection between the corrected orientation of the talus and tibia. Based on the requirements set by the orthopedic surgeon, specific regions of each bone were virtually removed by designing patient-specific guides. A Fortus 380mc 3D printer (Stratasys, USA) was used to develop an original-anatomical model, corrected-anatomical model, and each bone fragment for comparison in the operating room. A Figure 4 standalone 3D printer (3D Systems, USA) was used to develop the patient-specific cut guides. A successful surgery was completed at The Hospital for Sick Children, making it the first orthopaedic case to use the in-hospital point-of-care 3D printing service. With continual technological advancements in 3D printing and visualization techniques becoming more popular in the medical field, the importance of collaborating between biomedical engineers and surgeons is becoming more apparent.

Learning Objectives:

  • Identify the importance of collaborating between biomedical engineers and healthcare professionals within the medical 3D printing field
  • Visualize the importance of virtual surgical planning and 3D printing for complex congenital surgery
  • Learn how to use computer-aided design software and 3D printing in a unique, non-traditional way
  • Brandon Peel
    Biomedical Engineer
    The Hospital for Sick Children