ExMachina 3D Medical Modeling has experience since 2008 in the use of 3D printing technology for clinical purposes. That is why we chose the technology of 3D Stereolithography Apparatus (SLA) for the construction of our anatomical models and surgical guides. This is the first 3D printing technology that has been marketed and tested since 1986, and is still considered today the best technology for making models of high accuracy and quality without prohibitive costs, while allowing the use of materials, certified by authorized organizations internationally for their biocompatibility. The State-of-the-art SLA machines make models from liquid resin that solidifies in a controlled environment using lasers in fat layers of one tenth of a millimeter, to achieve the greatest possible accuracy in reproducing anatomical imaging data. Each model that is made goes through a strict quality control before delivery, while the surgical splints are tested in conventional (plaster) models of the teeth and in the mouth of the patients before the time of the surgery for greater safety. The international scientific literature and the research work of the company since 2008 as well as the clinical results have clearly proved the superiority of this technology.

1. 3D treatment design

Using 3D radiological data (eg from 3D computed tomography) and specialized software, we design and perform virtually any surgery on the skull bones, jaws and teeth, simulating the operation that the patient will undergo. This allows the surgeon to have a very good picture of the patient’s anatomy and the expected result, while giving the opportunity to make changes or corrections to the treatment plan until the best possible result is achieved.

2. 3D printing

Using the latest technology in 3D printing, we make with very high-precision anatomical models of the skull, jaws and teeth from 3D radiographic data, so that the surgeon can see and manipulate real models of the patient’s anatomy in their true dimensions. This helps a lot in planning the treatment and allows the surgeon to have a true picture of the patient’s bones in her hands, long before the time of surgery.

In addition, with this technology we manufacture personalized surgical guides, splints and other devices so that the virtual simulation of the operating room can be transferred with very high accuracy to the patient at the time of surgery.

3. 3D analysis of anatomical data

Using specialized software and 3D imaging data, we perform thorough analysis of the morphology of the bones and the soft tissues in order to extract qualitative and quantitative information about their shape. In this way, we study accurately whether the appearance of the face and the bones of the skull differ in 3 dimensions before and after an operation, how much they change over time will be, we accurately calculate the asymmetry between the left and right side of the face and determine the shape and volume of an implant that will be required to achieve perfect aesthetic symmetry, well before the time of surgery.

Orthognathic surgery is a reconstructive surgery that aims to move and reposition the lower and / or upper jaw in relation to the rest of the facial skeleton to correct skeletal abnormalities and improve function and aesthetics. The design for such a complex surgery must be done in 3 dimensions with precision of a millimeter.

In the past, this was done exclusively using x-rays and plaster models of the teeth, which the Dental Technician cut, moved and repositioned according to the surgeon’s instructions. This method had many limitations, such as not allowing the surgeon to have an accurate and comprehensive picture of the desired final relationship of the teeth to the rest of the skeleton of the face and skull.

Today, with the use of 3D imaging methods and specialized software, we simulate an orthognathic operation with much greater accuracy, having on our computer screen the entire skeleton and the soft tissues of the skull along with the teeth.

ExMachina 3D Medical Modeling allows the surgeon to go one step further: we make life-size models of the patient’s skull and jaws to the nearest millimeter, allowing the surgeon to manipulate these models to decide the treatment plan, to recognize anatomical structures such as pores of the skull where nerves and arteries pass and study the symmetry or asymmetry that each incident presents. Once the treatment plan is decided, we first perform it on these models allowing the surgeon to see the desired end result. When the surgeon is satisfied, we manufacture personalized guides and splints, so that this simulation of the operation can be transferred with the greatest possible accuracy to the operating room.