Dimensional Printing Research Articles

Individualized Design Application of 3-Dimensional Printing Navigational Template for Pedicle Screw Installation: A Training Case Report.

BACKGROUND The proper installation for pedicle screws by the traditional method of surgeons dependent on experience is not guaranteed, and educational solutions have progressed from chalkboards to electronic teaching platforms. We designed a case of 3-dimensional printing drill guide template as a surgical application, which can accurately navigate implantation of pedicle screws, and assessed its effect for simulative training. MATERIAL AND METHODS We randomly selected a set of computed tomography data for spondylolisthesis. A navigational template of pedicles and screws was designed by software Mimics and Pro-E, where trajectories of directions and angles guiding the nail way were manipulated for screwing based on anatomy, and its solid model was fabricated by a BT600 3D printer. The screws were integrated and installed to observe their stability. RESULTS The navigational model and custom spine implants were examined to be compatibly immobilized, because they are tolerant to radiation and stable against hydrolysis. The screw size and template were fit accurately to the vertebrae intraosseously, because the pilot holes were drilled and the trajectories were guided by cannulas with visible routes. During the surgical workflow, the patient reported appreciation and showed substantial compliance, while having few complications with this approach. Compared with fluoroscopy-assisted or free-hand techniques, the effect of simulative training during processing was excellent. CONCLUSIONS The surgical biomodel is practical for the procedural accuracy of surgical guides or as an educational drill. This fostering a style of "practice substituting for teaching" sets a paragon of keeping up with time and is worthy of recommendation.

Progress in organ 3D bioprinting.

Three dimensional (3D) printing is a hot topic in today’s scientific, technological and commercial areas. It is recognized as the main field which promotes “the Third Industrial Revolution”. Recently, human organ 3D bioprinting has been put forward into equity market as a concept stock and attracted a lot of attention. A large number of outstanding scientists have flung themselves into this field and made some remarkable headways. Nevertheless, organ 3D bioprinting is a sophisticated manufacture procedure which needs profound scientific/technological backgrounds/knowledges to accomplish. Especially, large organ 3D bioprinting encounters enormous difficulties and challenges. One of them is to build implantable branched vascular networks in a predefined 3D construct. At present, organ 3D bioprinting still in its infancy and a great deal of work needs to be done. Here we briefly overview some of the achievements of 3D bioprinting technologies in large organ, such as the bone, liver, heart, cartilage and skin, manufacturing.

Demographics, Utilization, Workflow, and Outcomes Based on Observational Data From the RSNA-ACR 3D Printing Registry

PurposeThe aim of this study was to report data from the first 3 years of operation of the RSNA-ACR 3D Printing Registry. MethodsData from June 2020 to June 2023 were extracted, including demographics, indications, workflow, and user assessments. Clinical indications were stratified by 12 organ systems. Imaging modalities, printing technologies, and numbers of parts per case were assessed. Effort data were analyzed, dividing staff members into provider and nonprovider categories. The opinions of clinical users were evaluated using a Likert scale questionnaire, and estimates of procedure time saved were collected. ResultsA total of 20 sites and 2,637 cases were included, consisting of 1,863 anatomic models and 774 anatomic guides. Mean patient ages for models and guides were 42.4 ± 24.5 years and 56.3 ± 18.5 years, respectively. Cardiac models were the most common type of model (27.2%), and neurologic guides were the most common type of guide (42.4%). Material jetting, vat photopolymerization, and material extrusion were the most common printing technologies used overall (85.6% of all cases). On average, providers spent 92.4 min and nonproviders spent 335.0 min per case. Providers spent most time on consultation (33.6 min), while nonproviders focused most on segmentation (148.0 min). Confidence in treatment plans increased after using 3-D printing (P < .001). Estimated procedure time savings for 155 cases was 40.5 ± 26.1 min. ConclusionsThree-dimensional printing is performed at health care facilities for many clinical indications. The registry provides insight into the technologies and workflows used to create anatomic models and guides, and the data show clinical benefits from 3-D printing.

Enhancing electromagnetic shielding property and absorption coefficients via constructing electromagnetic rings in janus composites

Polymer based electromagnetic wave (EMW) shielding materials with high conductivity have excellent electromagnetic shielding properties, but also exhibit high reflection of EMWs, resulting in inevitable secondary electromagnetic pollution. EMW shielding materials with low reflection have extensive potential applications in the next generation of anti-EMW equipment. Herein, a production strategy combining three dimensional (3D) printing technology and solution casting method was proposed to prepare polylactic acid (PLA)@multi-walled carbon nanotubes (MWCNT)/polydimethylsiloxane (PDMS)@carbonyl iron powder (CIP) absorptive electromagnetic shielding Janus composites with a ring-shaped electromagnetic synergistic structure (spiral rings or concentric circular rings). By utilizing PLA and MWCNTs as primary components, a 3D integrated framework that combines a highly conductive reflector and a ring inductance structure can achieve significant EMW shielding performance with low reflection. With PDMS as a matrix and magnetic CIP as functional fillers, a strong magnetic permeability network is provided around the ring inductance frame. The magnetic loss resulting from electromagnetic cooperative ring structure further enhances microwave absorption capacity. The composite materials, benefiting from the synergistic interaction between the electromagnetic rings and the reflector, demonstrate excellent impedance matching and efficient EMW shielding capabilities. Specifically, the PLA@MWCNT/PDMS@CIP Janus composites with ring structure exhibit a notable EMW shielding effectiveness (SE) of 31 dB and a reflection coefficient as minimal as 0.3. Therefore, this study presents a powerful approach to the development of low-reflective materials with high EMW SE, promising potential applications in the next-generation intelligent electronic devices.

The Use of Orthoses Made With 3D Printer In Upper Extremity Rehabilitation: A Review

Recent advancements in technology have brought about a significant transformation in the healthcare industry, particularly in the rehabilitation services sector, with the adoption of 3D (3 Dimensional) printing. This technology plays a crucial role in designing customized, aesthetically pleasing, lightweight, and eco-friendly orthoses for upper extremity rehabilitation. 3D scanning systems accurately predict the production process of orthoses, making it easier to maintain records of orthotic models. These recorded models make repetitive and batch production processes more efficient and accessible. However, the use of 3D printers in developing countries is limited due to high costs. Additionally, there is a lack of evidence-based practices. To overcome these challenges, efforts are underway to improve software interfaces for orthotic production and integrate 3D printed orthoses into upper extremity rehabilitation models. Further research is necessary to explore the optimal parameters for 3D printing in upper extremity orthotic production across diverse demographics.

Consumer's perceptions and motivations on the consumption of fortified foods and 3D food printing

Consumer attitudes and acceptance of emerging technologies in the food sector, as well as their application, are determining factors for their successful implementation. In this study, a survey was conducted in order to better know and understand the perception, motivation and consumption associated with fortified foods and 3DPF (3-Dimensional Printing Food). Key points such as food neophobia and factors involved in the opinion forming process towards 3DPF were included in the questionnaire (namely, perceived benefits, willingness to consume, food engagement, preference for familiar foods and affinity with digital tools). The results showed that the gender influences the knowledge in 3D printing as a technology and that 51.6 % of consumers are willing to try 3DPF. Consumers who want healthy food adapted to their needs are also more receptive to foods produced on 3D printers. 54.1 % of consumers indicate that if 3DPF were nutritionally richer than an equal and/or existing product on the market, they would be willing to buy it. Respondents also mentioned fruit and vegetable by-products and fish with no commercial value as the most suitable raw materials for 3D printing. Thus, it can be concluded that there is a clear motivation to try 3DPF, providing an opportunity for their inclusion in the future food chain.

Effect of 3D printing technology and print orientation on the trueness of additively manufactured definitive casts with different tooth preparations

ObjectivesTo evaluate the fabrication trueness of additively manufactured maxillary definitive casts with various tooth preparations fabricated with different 3-dimensional (3D) printers and print orientations. MethodsA maxillary typodont with tooth preparations for a posterior 3-unit fixed partial denture, lateral incisor crown, central incisor and canine veneers, first premolar and second molar inlays, and a first molar crown was digitized with an industrial scanner. This scan file was used to fabricate definitive casts with a digital light processing (DLP) or stereolithography (SLA) 3D printer in different orientations (0-degree, 30-degree, 45-degree, and 90-degree) (n = 7). All casts were digitized with the same scanner, and the deviations within each preparation site were evaluated. Generalized linear model analysis was used for statistical analysis (α = 0.05). ResultsThe interaction between the 3D printer and the print orientation affected measured deviations within all preparations (P ≤ 0.001) except for the lateral incisor crown and canine veneer (P ≥ 0.094), which were affected only by the main factors (P < 0.001). DLP-90 mostly led to the highest and DLP-0 mostly resulted in the lowest deviations within posterior tooth preparations (P ≤ 0.014). DLP-30 led to the lowest deviations within the first premolar inlay and DLP-45 led to the lowest deviations within the central incisor veneer preparation (P ≤ 0.045). ConclusionsPosterior preparations of tested casts had the highest trueness with DLP-0 or DLP-30, while central incisor veneer preparations had the highest trueness with DLP-45. DLP-90 led to the lowest trueness for most of the tooth preparations. Clinical Significance:Definitive casts with tooth preparations fabricated with the tested DLP 3D printer and the print orientation adjusted on tooth preparation may enable well-fitting restorations. However, 90-degree print orientation should be avoided with this 3D printer, as it led to the lowest fabrication trueness.

Tracking control of non-minimum phase systems: a kernel-based approach

Feedforward control with model inversion is a widely-used solution for high-precision output tracking. However, because inverting a non-minimum phase model generates unbounded control input, model-inversion only applies to limited types of systems. This paper presents a new non-parametric pseudo-inversion approach to design bounded optimal control input with desirable properties for arbitrary types of systems. Closed-form equations are presented for the batch (full preview) and recursive (limited preview) implementations of this approach, and its performance is compared against existing pseudo-inversion methods in benchmark numerical examples. Furthermore, the practical implementation of the proposed method is demonstrated by designing a feedforward controller for a commercial 3-Dimensional (3D) printer. The results show that the proposed approach effectively compensates for the structural vibrations of the printer, preventing layer-shifting errors that usually happen during high-speed printing.

All-printed 3-dimensional micro-supercapacitors with homogeneous Ag interface: Achieving precision on curved surfaces through Electrohydrodynamic jet printing

Despite advancements in manufacturing techniques for micro-supercapacitors (MSCs), significant challenges remain in achieving on-chip miniature devices that conform to complex surfaces, which is crucial for the seamless integration in advanced electronic systems. This study utilizes direct electrohydrodynamic (EHD) 3-dimensional (3D) printing to fabricate all-printed MSCs on planar and curved surfaces, employing Ag as a base material for both current collectors and electrodes to ensure homogeneous interfaces throughout the printed structures. Our approach uniquely manipulates the applied nozzle voltage in the EHD 3D printing process to achieve finely controlled and uniform 3D structures on both flat and curved surfaces. The high-precision EHD jet printer produces MSCs with notably narrow electrode linewidths of approximately 144μm. A 3D MSC cell is then fabricated with 15 EHD 3D-printed stacked layers to achieve a remarkable electrode-line height/width (h/w) ratio of 4.2, which exhibits exceptional electrical performance with an areal capacitance of 763.1 mF cm−2 and energy density of 256.6 μWh cm−2. Additionally, multiple MSCs are EHD 3D-printed on a curved substrate to successfully energize an LED. These findings verify that EHD 3D printing can be utilized to fabricate scalable energy storage devices that can be easily integrated with the next generation electronic systems.

StepBrain: A 3-Dimensionally Printed Multicompartmental Anthropomorphic Brain Phantom to Simulate PET Activity Distributions.

An innovative multicompartmental anatomic brain phantom (StepBrain) is described to simulate the invivo tracer uptake of gray matter, white matter, and striatum, overcoming the limitations of currently available phantoms. Methods: StepBrain was created by exploiting the potential of fused deposition modeling 3-dimensional printing to replicate the real anatomy of the brain compartments, as modeled through ad hoc processing of healthy-volunteer MR images. Results: A realistic simulation of 18F-FDG PET brain studies, using target activity to obtain the real concentration ratios, was obtained, and the results of postprocessing with partial-volume effect correction tools developed for human PET studies confirmed the accuracy of these methods in recovering the target activity concentrations. Conclusion: StepBrain compartments (gray matter, white matter, and striatum) can be simultaneously filled, achieving different concentration ratios and allowing the simulation of different (e.g., amyloid, tau, or 6-fluoro-l-dopa) tracer distributions, with a potentially valuable role for multicenter PET harmonization studies.

Does a Point-of-Care 3-Dimensional Printer Result in a Decreased Length of Surgery for Orbital Fractures?

Utilization of point-of-care 3-dimensional printing (3DP) has decreased length of surgery in facial trauma. Little is known regarding 3DP's impact on length of surgery in orbital fracture. The purpose of this study was to compare length of surgery between 3DP/preadapted (3DPPA) orbital plates and intraoperative adapted plates (IOAP) for orbital fracture reconstruction. This was a prospective, non-blinded, randomized clinical study of consecutive subjects with orbital fractures presented to Grady Memorial Hospital in Atlanta, Georgia, between January 2018 and June 2021. Subjects ≥ 18years, unilateral fracture, no previous orbital surgery, and/or congenital craniofacial anomaly were included. We excluded subjects <18years and bilateral fractures. Primary predictor variable was the treatment approach. Randomization software was used, and subjects were randomized to 3DPPA or IOAP groups. Primary outcome variable was length of surgery in minutes. Secondary outcomes were the time required for plate insertion and fixation in minutes, operating room (OR) charges, and orbital volume (OV) calculation. Age, sex, race, etiology, laterality, location, dimension, indication for surgery, postoperative enophthalmos, and diplopia. Univariate and bivariate analyses were calculated. Statistical significance was P<.05. Twenty-five subjects met the inclusion criteria. Mean ages in 3DPPA and conventional IOAP groups were 41.5 (±9) and 38.2 (±10, P=.31), respectively. The mean length of surgery was 32.6 (±13.7) in 3DPPA and 53.3 (±12.8, P<.001) in conventional IOAP. The mean time required for plate insertion and fixation was 15.8n (±14.4) in 3DPPA and 41.4 (±9.4, P<.001) in conventional IOAP. The mean OR charges were $1,072.5 (±524.6) in 3DPPA and $1,757.3 (±422.6, P ≤ 0.001) in conventional IOAP. The mean calculated OV of uninjured and reconstructed orbit for the 3DPPA was 23.5 (±3.2)cm3 and 23 (±3.5, P=.37)cm3, respectively. The mean calculated OV of uninjured and reconstructed orbit for conventional IOAP was 28.6 (±3.6)cm3 and 22.8 (±2.6, P<.001)cm3, respectively. Using 3DP to produce a model that enables preoperative plate bending/adaptation reduces the length of surgery, decreases OR charges, and results in predictable OV.

Autologous Tissue Repair and Total Face Restoration

Total face restoration remains a challenge in modern reconstructive surgery. After 17 years of experiments and preliminary clinical studies, a new concept of face prefabrication was developed for face restoration with autologous tissue. To evaluate the long-term results of face restoration with autologous tissue and report a finalized and standardized approach of face prefabrication. In this single-center long-term retrospective study, 32 patients who underwent total face restoration between 2005 and 2022 were reviewed. These patients underwent total facial reconstruction, which included flap prefabrication, 3-dimensional printing, tissue expansion, and flap transfer with aid of indocyanine green angiography (IGA). The flap first undergoes prefabrication by transferring vascularized fascia under the skin of the selected chest. A tissue expander is then placed under the fascia to create a large, thin, reliable skin flap after expansion. Once completed, the flap is transferred to the face during the second stage of the reconstruction. Intraoperative IGA is performed to guide the design of subsequent openings for facial fissures. Data were analyzed from July to September 2023. Flap healing, reconstructive outcome, and patient recovery were assessed during follow-up. Three questionnaires, including the 36-Item Short Form Health Survey (SF-36), Aesthetic and Functional Status Score of Facial Soft-Tissue Deformities/Defects, and the EuroQoL Health-Related Quality of Life (EQ-5D-5L), were used to evaluate the quality of life and satisfaction with facial aesthetic and functional status. Of 24 included patients, 14 (58%) were male, and the mean (range) age was 32.9 (8-62) years. The mean (range) follow-up was 5.6 (2-12) years. All patients reported a significant improvement in quality of life (SF-36), especially in mean (SD) social functioning (preoperative score, 53.65 [34.51]; postoperative score, 80.73 [19.10]) and emotional stability (preoperative score, 56.67 [25.55]; postoperative score, 71.17 [18.51]). A total of 22 patients (92%) went back to work. Mean (SD) facial aesthetic status (preoperative score, 4.96 [3.26]; postoperative score, 11.52 [3.49]; P < .001) and functional status (preoperative score, 11.09 [3.51]; postoperative score, 15.78 [3.26]; P < .001) also improved. In addition, there was a significant increase in overall satisfaction and self-reported health status (preoperative score, 8.13 [1.52]; postoperative score, 3.58 [2.31]). In this study, 5-year follow-up results suggested that this innovative approach to total face restoration offered a safe and valid option for indicated patients, with acceptable reconstructive and cosmetic outcomes.

Modernizations of graphene nanocomposites using synthesis strategies—State-of-the-art

Graphene has been ranked among one of the most remarkable nanostructures in the carbon world. Graphene modification and nanocomposite formation have been used to expand the practical potential of graphene nanostructure. The overview is an effort to highlight the indispensable synthesis strategies towards the formation of graphene nanocomposites. Consequently, graphene has been combined with useful matrices (thermoplastic, conducting, or others) to attain the desired end material. Common fabrication approaches like the in-situ method, solution processing, and melt extrusion have been widely involved to form the graphene nanocomposites. Moreover, advanced, sophisticated methods such as three- or four-dimensional printing, electrospinning, and others have been used to synthesize the graphene nanocomposites. The focus of all synthesis strategies has remained on the standardized graphene dispersion, physical properties, and applications. However, continuous future efforts are required to resolve the challenges in synthesis strategies and optimization of the parameters behind each technique. As the graphene nanocomposite design and properties directly depend upon the fabrication techniques used, there is an obvious need for the development of advanced methods having better control over process parameters. Here, the main challenging factors may involve the precise parameter control of the advanced techniques used for graphene nanocomposite manufacturing. Hence, there is not only a need for current and future research to resolve the field challenges related to material fabrication, but also reporting compiled review articles can be useful for interested field researchers towards challenge solving and future developments in graphene manufacturing.

Accuracy of immediately placed implants using surgical guides from different 3-dimensional printers: An in vitro study.

The aim of this study was to evaluate the accuracy of 3-dimensional (3D)-printed surgical guides for fully guided immediate implants from different manufacturers. Eighteen 3D printed fully guided surgical guides (split into 3 groups [n = 6] according to their manufacturer: Company, Desktop, or Lab), were used to place 72 implants (n = 24) in identical maxillary models. After placement, the mean global, angular, mesiodistal, buccopalatal, and vertical deviation at the platform and apex of the placed implants, relative to their preoperatively planned positions, was calculated. Significant differences in global apex deviation, angular deviation, mesiodistal apex deviation, and vertical platform and apex deviation were found between the Lab and Desktop groups (p ≤ 0.007). Significant differences in mesiodistal platform and apex deviation and buccopalatal apex deviation were also found between the Company and Desktop groups (p ≤ 0.005). Finally, significant differences in buccopalatal apex deviation, and vertical platform and apex deviation were found between the Company and Lab groups (p ≤ 0.003). Mean differences between guide groups across all parameters never exceeded 0.5 mm or 1°. The choice of 3D printer has a significant effect on the accuracy of fully guided immediate implants. However, the clinical relevance of these differences may be considered limited.

Effects of infill pattern and compression axis on the compressive strength of the 3D-printed cubic samples

Abstract Structures that are very difficult to produce with classical manufacturing methods have become easily produced with the development of additive manufacturing (AM) technique. AM technique allows creating special infill patterns with gaps in the internal structures of the products to be produced. These special infill patterns ensure that the product has maximum rigidity and strength while also providing minimum mass. For this reason, it is important to investigate the effects of infill patterns produced by AM technique on the mechanical properties of the product. In this study, the compression characteristics of compression test samples produced in five different infill patterns (octet, grid, cubic, quarter cubic, gyroid) using the AM method were experimentally investigated in three different axes. Test samples were produced from PLA material with a 3-dimensional (3D) printer in accordance with the ASTM C365-16 standard. Compression tests were repeated three times at a compression speed of 0.5 mm/min, with five different infill patterns and three different axes for each parameter. According to the results obtained, the octet infill pattern provided the best compressive strength in all three axes. It has been determined that the infill pattern or load axis change greatly affects the compression performance of the product.

Development and Preliminary Evaluation of A Soft Tissue Microtia Simulator.

Surgical simulation has been used extensively for learning microtia reconstruction and has almost exclusively involved framework creation. However, soft tissue reconstruction in microtia is equally challenging and would benefit from a simulation platform. This study aimed to describe the development and preliminary evaluation of a high-fidelity soft tissue microtia simulator. Three-dimensional modeling software, fused deposition 3-dimensional printing, adhesive techniques, silicones, and polyurethane rubbers were utilized to create a right lobular-type microtia simulator that comprises skin, subcutaneous tissue, and cartilage. Two expert microtia surgeons performed a microtia reconstruction on the simulator and evaluated its value and realism using a Likert-type questionnaire. The surgeons utilized a previously developed synthetic framework and successfully performed the critical steps of the soft tissue reconstruction, including marking, incising, dissection, removal of the cartilage remnant, drain insertion, insertion of the framework, closing of the skin, and demonstration of the soft tissue conforming over the framework using suction. A preliminary assessment of the simulator demonstrated that the simulator is anatomically accurate, realistic, and highly valuable as a training tool. A high-fidelity soft tissue microtia simulator was successfully developed and tested. The simulator provides a valuable training platform for learning a critical component of microtia reconstruction.

The 3D-Printed Custom Elbow Prosthesis for Salvage Treatment of Complex Intra-Articular Distal Humerus Fracture Malunion

Intra-articular fractures of the distal humerus are complex injuries that often require surgery with the goal of restoring elbow range-of-motion and function. Open reduction and internal fixation has been the preferred surgical modality; however, restoration of the medial and/or lateral columns can be complicated in fractures involving a major loss of the articular surface and bony structure. Over the past decade, 3-dimensional (3D) printing has made significant advances in the field of orthopedic surgery, specifically in guiding surgeon preoperative planning. Recently, the incorporation of 3D-printing has proven to provide a safe and reliable construct for the restoration of anatomy in complex trauma cases. We present a 47-year-old woman who sustained a complex, intra-articular distal humerus fracture with associated shearing of the capitellum that went onto malunion. Patient was treated with a patient-specific 3D-printed custom elbow prosthesis with excellent outcomes. Our goal was to shed light on the use of 3D-printing technology as a viable salvage option in treating complex, intra-articular distal humeral fractures associated with lateral condylar damage that subsequently went onto malunion.

Virtual Reality vs Phantom Model: Benefits and Drawbacks of Simulation Training in Neurosurgery.

Traditional neurosurgical education has relied heavily on the Halstedian "see one, do one, teach one" approach which is increasingly perceived as inefficient in contemporary settings marked by a steady decline in surgical caseload. In recent years, simulation training has emerged as an effective and accessible training alternative. To date, however, there is no standardized criterion pertaining to the quality and implementation of simulators in neurosurgical education and training. This research aims to compare the efficacy of virtual reality (VR) and Phantom-based simulation training in the context of neurosurgical skill acquisition, with a focus on middle cerebral artery aneurysm clipping. An immersive VR clipping tool and a haptic clipping simulator incorporating 3-dimensional printing, additive manufacturing, and rheological analyses were developed. Twenty-two participants, comprising 12 medical students, 6 neurosurgical residents, and 4 experienced neurosurgeons, tested and evaluated both simulators for face and content validity. Construct and predictive validity of the simulators were assessed using an objective structured assessment scale for aneurysm clipping, measuring participants' performances and progress. Both modalities were deemed highly advantageous for educational purposes. Objective evaluations, however, revealed measurable differences in usability, efficacy, and transferability of the learned skills with VR excelling in procedural planning and visualization while Phantom simulation being noticeably superior in conveying surgical skills. Simulation training can accelerate the neurosurgical learning curve. The results of this study highlight the importance of establishing standardized criteria for the implementation and assessment of simulation modalities, ensuring consistent quality and efficacy in neurosurgical education.

3-Dimensional printing for training in emergency medicine

3-Dimensional printing for training in emergency medicine

The development of direct 3-dimensional printing of patient-specific mitral valve in soft material for simulation and procedural planning

ObjectivesReplicating 3-dimensional prints of patient-specific mitral valves in soft materials is a cumbersome and time-consuming process. The aim of this study was to develop a method for a direct 3-dimensional printing of patient-specific mitral valves in soft material for simulation-based training and procedural planning. MethodsA process was developed based on data acquisition using 3-dimensional transesophageal echocardiography Cartesian Digital Imaging and Communication of Medicine format, image processing using software (Vesalius3D, Blender, Meshlab, Atum3D Operation Station), and 3-dimensional printing using digital light processing, an additive manufacturing process based on photopolymer resins. Experiments involved adjustment of 3 variables: curing times, model thinness, and lattice structuring during the printing process. Printed models were evaluated for suitability in physical simulation by an experienced mitral valve surgeon. ResultsDirect 3-dimensional printing of a patient's mitral valve in soft material was completed within a range of 1.5 to 4.5 hours. Prints with postcuring times of 5, 7, 10, and 15 minutes resulted in increased stiffness. The mitral valves with 2.0-mm and 2.4-mm thinner leaflets felt more flexible without tear of the sutures through the material. The addition of lattice structures made the prints more compliant and better supported suturing. ConclusionsDirect 3-dimensional printing of a realistic and flexible patient-specific mitral valve was achieved within a few hours. A combination of thinner leaflets, reduced curing time, and lattice structures enabled the creation of a realistic patient-specific mitral valve in soft material for physical simulation.