3matic Clinical E

3-matic Application
Making the headwork easier

3-matic allows for fast, easy digital design of a prosthesis for cranioplasty
W hen a cranial plate needs to be constructed, the objective is always to

recreate the skull’s geometry. Since the cranial plate needs to fit perfectly
on the patient’s skull you need to incorporate scanned anatomical data into
the design. This is usually a rather complex and time-consuming task. 3-matic
however can work directly on the data generated by the image processing
software, which results in considerable time-savings. In addition, the software
provides the necessary tools for easily designing even the most complex
prostheses, like those for defect crossing the skull’s midline.
Fast design of a cranial plate

First we made an outline of the defect (see the orange line in Fig. 1) on the 3D model
of the scanned skull. Fig. 1
Thanks to 3-matic’s sketcher, you can design arches in the defect (see the blue line in
Fig. 1 and the black line in Fig. 2) if necessary. These arches define the height and shape
of the resulting prosthesis.
The software’s advanced surface reconstruction tool can next create the cranial plate
automatically. You simply need to define some parameters for the plate’s thickness and
its clearance with the bone. In this case it took about 10 minutes to design the plate.
Furthermore, 3-matic software offers a wide range of tools for quickly crafting a complete
3D design of the prosthesis, including perforations, lugs etc (see Fig. 3). For example:
a lug for this cranial plate was created in 5 minutes. Since its design follows the skull’s
curvature (see Fig. 4) you ensure a perfect fit with the skull.
Easy integration of anatomical geometry

3-matic is an ideal tool for integrating anatomical structures into a design. Such designs
are impossible in CAD software without lengthy reverse engineering. Adapting the Fig. 2
resulting files is usually large and complex.
3-matic simplifies that process significantly. You can work directly on the data generated
by the image processing software. And, being triangle-based software, 3-matic facilitates
a lot of tasks that are hard or even impossible to do in traditional CAD. One such task is
integrating anatomical data.
Why choose 3-matic?

Saves time: Because you can work directly on the scanned data
Simplifies complex designs thanks to the advanced design
operations Fig. 3
Ensures a perfect fit by incorporating the anatomical geometry in
the design
When to choose 3-matic for implant design?

For designs requiring integrated anatomical structures like
custom hip and knee prostheses (see verso) and for custom
surgical aids (guides etc)
For organic designs like cranial and maxillofacial implants
Fig. 4
w w w. m a t e r i a l i s e . c o m / 3 - m a t i c - 3-matic@materialise.com
3-matic Application
Tumor no longer brings the patient to his knees

Effortless design of a custom preformed titanium membrane
I n case of bone tumors the treatment aims at an ideal reconstruction of the

weight-bearing bones after tumor resection, which translates as biological
affinity, resistance to infection and sufficient biomechanical strength and
Fig. 1
durability. During surgery, the tumor is excised, while an implant is placed to

guarantee the strength of the bone. Such implants can be produced through
hydro-forming where a titanium membrane is pressed on a kind of mold. 3-matic
software provides the necessary tools for pre-operative planning and the design
of the stereolithography master model for casting. Using a digital route - 3-matic
- ensures accuracy and results in serious time gains.
Below we describe in more detail how 3-matic facilitates the design of the preformed
membrane. It’s the clinical case of an 18-year old male professional swimmer suffering Pre-operative planning:
from a juxtacortical chondroma at posterior-medial site of distal femur. yellow: tumor - green: implant’s maximal outline
Fig. 2
Clear visualization of the tumor
CT images from scanning the patient’s knee were processed with Mimics, resulting in
an accurate 3D computer model of the bone. The Mimics model offered a clear visual
of the deformed bone (tumor). This model is of great assistance for the pre-operative
planning and the design of the implant.
Pre-operative planning in a few minutes

3-matic software’s advanced curve technology allows you to create, select, separate or
combine surfaces with ease. This way you can easily select the tumor (Fig. 1: yellow
area) that needs to be removed and design the implant. The green area you see in Fig.
1 is the maximum outline of the titanium membrane. This outline is selected in such a Design of ‘new’ bone shape
way that it ensures a firm fit of the membrane on the remaining bone.
Fig. 3
Easy design of the membrane
Next, the surface representing the deformed bone is removed. 3-matic’s innovative
surface construction algorithm generates a new surface (Fig. 2: purple area) that
reconstructs the original bone shape. The new bone shape is then combined with the
outlined surface into the final shape for the membrane. Based on this design the hydro-
forming tool is created. Using 3-matic the hydro-forming shape (Fig. 3) is designed in
less than 10 minutes just by combining the reconstructed bone shape with a cylindrical
shape. Next this design is inverted to create a negative 3D model, which will be used
for casting.
Cost-efficient, fast manufacturing of custom implant

The negative hydro-forming shape can be produced quickly and cost-efficient using Design of hydro-forming shape
stereolithography. The resulting model is cast to create the hydro-forming tool, which
will produce the membrane (Fig. 4). Fig. 4
Successful bone reconstruction surgery

During surgery the tumor is removed according to the pre-operative planning and filling
material is placed. After that the membrane is implanted. Thanks to its personalised
shape it fits perfectly on the remainder of the bone. This type of implant will provide
enough strength for weight bearing applications.
Hydro forming result
w w w. m a t e r i a l i s e . c o m / 3 - m a t i c - 3-matic@materialise.com

3matic Clinical E

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3-matic Application

Making the headwork easier

W hen a cranial plate needs to be constructed, the objective is always to

Fast design of a cranial plate

Easy integration of anatomical geometry

Why choose 3-matic?

When to choose 3-matic for implant design?

Tumor no longer brings the patient to his knees

I n case of bone tumors the treatment aims at an ideal reconstruction of the

durability. During surgery, the tumor is excised, while an implant is placed to

Pre-operative planning in a few minutes

Cost-efficient, fast manufacturing of custom implant

Successful bone reconstruction surgery

Hydro forming result

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