Combined 3D Services
3D Printed Bone Models for Pre-Surgical Planning: Better Outcomes, Less OR Time
By Mike Moussa, PE — We convert CT and MRI data into physical bone models that surgeons hold in their hands before they pick up a scalpel. Here’s why it matters and how it works.
Why Surgeons Want Physical Models
A screen shows you a 2D slice. A 3D-printed model shows you the actual anatomy — the fracture pattern, the bone quality, the spatial relationships between structures. You can rotate it, mark on it, rehearse the approach, and pre-bend hardware.
The research backs it up:
- 20-30% reduction in operating room time — surgeons who rehearse on models work faster and more confidently
- Reduced revision rates — better planning means fewer surprises and fewer do-overs
- Improved patient communication — showing a patient their anatomy builds trust and informed consent
- Resident and fellow training — teach complex procedures on patient-specific anatomy before the real case
Applications by Specialty
Orthopedic Trauma
Complex fractures — especially pelvis, acetabulum, tibial plateau, and calcaneus — benefit enormously from physical models. Pre-contour plates, plan screw trajectories, and understand fragment displacement before the patient is on the table.
Joint Replacement
Patient-specific models for total hip, total knee, and shoulder arthroplasty planning. Evaluate bone stock, plan component sizing, and identify anatomical variants that could complicate the case.
Spine Surgery
Complex spinal deformity, tumor resection, and revision cases. Visualize pedicle morphology, plan screw placement, and understand the 3D relationship between the pathology and critical structures.
Craniomaxillofacial
Tumor resection planning, mandible reconstruction, orbital floor repair. Pre-bend reconstruction plates on the model instead of in the OR. Design cutting guides that snap onto the bone surface for precise osteotomies.
Pediatric Orthopedics
Congenital deformities, growth plate fractures, and corrective osteotomies. Small bones and complex anatomy make planning even more critical. Models help communicate plans to families.
From CT Scan to Physical Model
Step 1: Send Us the Imaging Data
We accept DICOM files from CT scans (preferred) or MRI. Higher resolution scans produce better models — we recommend 1mm or thinner slices. Your radiology department can export DICOM to a CD or secure transfer.
Step 2: Segmentation
We isolate the bone anatomy from surrounding soft tissue using medical imaging software. This creates a 3D digital model of the specific anatomy you need. We can isolate individual bones, show fracture fragments separately, or include specific landmarks.
Step 3: 3D Printing
The digital model is 3D printed in materials appropriate for your application:
- PLA or ABS — most common, rigid, lightweight, affordable. Perfect for visualization and plate pre-contouring.
- Flexible resin — simulates bone flexibility for practicing osteotomies or hardware placement.
- Clear resin — see-through models showing internal anatomy, tumor location, or hardware position.
- Multi-color — different colors for fracture fragments, tumors, or anatomical landmarks. Makes orientation intuitive.
- Sterilizable materials — ULTEM or autoclavable resin for models that go into the sterile field.
Step 4: Delivery
Models are typically delivered within 3-5 business days from receiving DICOM data. Rush service (24-48 hours) available for urgent cases.
Cost
| Model Type | Cost | Turnaround |
|---|---|---|
| Single bone (femur, humerus, etc.) | $150-$300 | 3-5 days |
| Complex joint (pelvis, shoulder) | $300-$600 | 3-5 days |
| Spine segment (3-5 levels) | $200-$400 | 3-5 days |
| Full skull or mandible | $400-$800 | 5-7 days |
| Custom cutting guide | $500-$1,200 | 5-7 days |
| Rush service (any model) | +50% | 24-48 hours |
Compare this to the cost of an extra 30-60 minutes of OR time ($50-150/minute at most facilities). A $300 model that saves 30 minutes pays for itself 5-15x over.
HIPAA and Data Security
We understand that DICOM files contain protected health information. We accept data via secure transfer, process it on encrypted systems, and delete imaging data after model delivery unless you request otherwise. We’re happy to sign a BAA (Business Associate Agreement) if required by your institution.
Get Started
If you’re a surgeon, PA, resident, or hospital administrator interested in 3D-printed surgical models, let’s talk. We can do a trial case at reduced cost so you can evaluate the quality and workflow.
📧 info@partsnap.com | 📞 (214) 449-1455 | Request a Trial Case