Making Surgery More Successful By Going Small

Surgeons had access to models of human vascular systems before 3D printing came along. But they were complicated to manufacture and costly to procure, at about $12,000.

Now, a University at Buffalo team is 3D-printing models for as little as $100—and they’re phenomenally precise, able to replicate the tiny vessels of a patient’s vascular system down to a mere 4 micrometers in width (that’s about the width of a strand of spider web silk). What’s more, these custom-made prints mimic not only vascular structure, but also some of its mechanical properties, making them a near-perfect duplicate.

These advanced models are a vital resource for surgeons preparing for the delicate procedures that treat the life-threatening conditions that cause stroke, aneurysms and cardiac arrest.

“We are trying to help surgeons who have really difficult cases, and have doubts about the approach,” says Ciprian “Chip” Ionita, assistant professor in the Department of Biomedical Engineering, who has successfully created models for about a dozen cases thus far.

The process starts with a real-life diagnosis. A scan of the patient’s affected area is taken through 3D medical imaging. Engineers then develop a geometric “blueprint” that guides the 3D printing.

The built-to-scale model, called a phantom, can be made on-site in the lab in as little as 20 minutes, depending on how complex the model needs to be and on the types of materials used to create the right texture. Most use rubber silicone, which best mimics blood vessels and can be warmed up to even better simulate the gummy elasticity of arteries.

Depending on the case, the print can be used for different applications, from understanding blood flow to creating a customized surgical plan. And if a surgical approach doesn’t work on the model, doctors can adjust it—before any scalpels ever touch human skin.

While 3D printing has been around for a while, only within the last decade has it infiltrated the healthcare system through medical imaging. Working in close collaboration with Adnan Siddiqui, professor of neurosurgery in the Jacobs School of Medicine and Biomedical Sciences, Ionita is exploring coronary, cardiac and now neuro applications. He predicts that 3D printing will become standard in all medical fields, noting that intensive teamwork among engineers, scientists and physicians is the key to its success.