Stereolithographic model construction based on 3-dimensional reconstructed CT sectional image sequences

Techniques for 3D reconstruction of medical objects and production of models by CAM have been markedly improved. Milling tools have limited abilities to reproduce complex anatomical structures. Even if 5-axis milling systems are used, the problem of collisions between tool and object is not yet under control. An alternative is offered here by stereolithography. We performed a computed tomography (Somatom DRH, Siemens/Erlangen) of a child with extensive maxillary bone defect after surgical treatment of a congenital tumour. The bone defect was covered by an alloplastic implant. 3D reconstructions were performed by the aid of a conventional personal computer. Generated 3D volume data sets were transferred to a stereolithography system (3D Systems GmbH, Darmstadt/FRG). The produced model revealed high accuracy of the anatomical structures. Intraoperatively, the alloplastic prosthesis was removed and the shape of the new implant could be designed using the stereolithographic model.