CAD aided pre-operative planning and prototyping of HTPLA orthopaedic femoral cutting guide

Fused Deposition Modeling (FDM) 3D printing technology has widespread in a variety of scientific fields, since rapid prototyping and low-cost investments well meet flexibility of application. Mechanical engineering is taking an essential role in Orthopaedics and Traumatology. As a patient-specific approach and minimally invasive surgeries are progressively needed in today’s medical routines, highly-customized 3D printed devices and surgical instruments represent a milestone in medical equipment. Virtual preoperatory planning and computer aided surgical simulations (CASS) enhance 3D visualization of human anatomy, giving doctors full understanding of traumas and deformities. Custom cutting guides (CCGs) represent the cutting edge of patient-dedicated surgical routines, allowing for a sensible reduction of operative time and risk of human error. While maxillofacial surgery (MFS) has already adopted customized 3D printed tools, pediatric orthopaedics (PO) and general long bones surgery strive to put these devices into common practice. Limitations to a large-scale implementation rely on collaboration with the industrial world, as engineering and designing skills are inevitably demanded. Here displayed is the prototype for a femoral cutting guide designed for a pediatric application of the IOR - Rizzoli Orthopaedic Institute of Bologna. The device was printed in a High-Temperature PLA, supporting common steam heat sterilization and maintaining designed geometry.