3D-printed jaw implant a first

In an Australian-first surgical procedure, a custom-made 3D-printed prosthetic jaw joint has successfully corrected a congenital jaw deformity in a young man.

Designed and created in Melbourne, the titanium jaw implant is the result of a collaboration between the University of Melbourne, medical devices company 3D Medical (ASX:3DM) and Epworth Hospital.

The recipient, Richard Stratton, was born with condylar aplasia which caused him to lack a temporomandibular joint (TMJ) on one side of his jaw. This resulted in insufficient growth on the left side of his face and a noticeable asymmetry in his lower jaw.

The condition also affected his jaw motion, making chewing difficult and affecting his facial expression. In the past few years, Stratton had suffered increasing pain while chewing or moving his jaw and was not been able to fully open his mouth.

Oral and maxillofacial surgeon Dr George Dimitroulis designed a prototype prosthesis and worked with research engineers from Melbourne University’s mechanical engineering department and 3D Medical to develop, engineer and test the joint replacement.

“Working closely with maxillofacial surgeon Dimitroulis, we helped to design, engineer and test this entirely new jaw joint prosthesis using state-of-the-art computational modelling we developed at the University of Melbourne,” said Dr David Ackland, a senior lecturer and researcher in experimental muscle and joint biomechanics at the University of Melbourne.

CT scan images were used to print a 3D plastic model of Stratton’s skull. Melbourne-based 3D Medical then used powdered titanium and 3D-printing technology to build the part one layer at a time — providing a part with a perfect fit.

In early May, Dimitroulis led the surgical team that implanted the custom-made titanium jaw joint replacement and the biomechanical and clinical results looked promising.

“We believe the techniques we have developed and the latest 3D-printing technology will facilitate a new direction in research and manufacture of implantable devices.”

Dimitroulis said that there had been a handful of 3D-printed jaw operations worldwide, but he was not aware of any that incorporated a titanium part and a 3D-printed plastic jaw joint.

“In terms of joint replacement specifically, what we call the TMJ - the temporomandibular joint - we suspect that this may be the first 3D-printed jaw joint in the world,” he said.

Dimitroulis believes surgery is at a crossroads and predicts that the increased use of 3D technology will lead to customised medical devices becoming an integral part of health care in this century.

“This case highlights the talents and capabilities we have here in Australia to design, develop and manufacture our own high-tech medical devices,” Ackland said.