To create a 3D-printed model for medical training, the first step is to select a case with a specific disease or pathology.[17] Image acquisition using rotational DSA, MRI, or CT with contrast is then necessary to generate high-quality 3D images in specialized software.[18] Specific imaging guidelines can help optimize the accuracy of converting 2D images to a 3D object. After acquiring the imaging data set, it is transferred into a 3D printing software for segmentation, processing, and creation of an STL file that can be printed.
In our study, we used Materialise Mimics, an FDA-approved software, for segmenting the pelvic endovascular model. To ensure accurate segmentation, only relevant series or preferred slices of images from each acquisition should be imported into the 3D printing software due to data storage limitations and the risk of misinterpretation by the software. In our case, we used the artery phase of the pelvic CT and specified images from the abdominal aorta near the aortic bifurcation to the femoral segment containing the femoral pseudoaneurysm. Finally, before printing, a CAD software is used to create an STL file.
The exported STL file from segmentation software may contain errors and is typically not optimal for printing, thus requiring repair and refinement in CAD software. In CAD software, post-processing steps such as fixing, wrapping, and smoothing, as well as co-registration of multiple model parts can be performed to ensure that the CAD model is in a printable state. There are several CAD software options available for mesh editing, including Meshmixer (Autodesk, Inc., San Rafael, CA), Meshlab (available at https://www.meshlab.net/), Thinkercad (AutoDesk® Inc., USA), and FreeCAD (open source, LGPL license) [19]. While segmentation and STL-refinement CAD are two distinct categories of software, software suites such as Mimics Innovation Suite (Materialise, Leuven, Belgium) and Mimics inPrint (Materialise, Leuven, Belgium) offer solutions to both functions. In our study, we utilized the Mimics Innovation Suite, which includes Materialise Mimics and Materialise 3-Matic for this 3D printing simulation model [19].
According to the American Society for Testing and Materials (ASTM), there are seven types of 3D printing methods, including vat polymerization, material jetting, binder jetting, material extrusion, powder bed fusion, sheet lamination, and directed energy deposition [20–21]. In our study, vat polymerization was used for printing due to its ability to print hollow vessel lumens without solid support material by orienting them straight to avoid internal support inside the vessels that are difficult to remove, especially in small, long or tortuous vessels. Additionally, vat polymerization is an accurate printing method that enables a 3D model to be printed with small vessel structures.
3D printing models have gained recognition as a valuable educational tool for learning anatomy and pathology. Moreover, they have proven to be of great value in assisting surgical planning and simulation of various procedures, thereby enhancing surgical care and patient management. The accuracy of 3D printing models, which are created using patient anatomy or segmented images, is crucial for ensuring effective surgical planning, education and training, patient communication, and patient safety in various medical applications.
The accuracy of 3D printing in replicating patient anatomy has been investigated in studies dating back to 1994, such as the one conducted by Barker et al. [22] In their study, a dry skull was imaged using CT, and the resulting images were used to create a segmented bone model that was then 3D printed using state-of-the-art software and hardware at that time. The study found that the average difference of 11 distances between anatomic landmarks measured on the cadaveric bone and those measured on the 3D printed model using a caliper was 1.8 mm, with a range of 0.10–4.62 mm (0.6%-3.7%). This demonstrated the relatively small margin of error in the accuracy of the 3D printing process in replicating patient anatomy.
Several studies in the literature [23, 24], in addition to the work by Barker et al, have investigated the accuracy of 3D printed models by comparing them with the raw data of segmented models using various 3D printing technologies. These studies have assessed the ability of 3D printing to replicate patient anatomy for a wide range of anatomical structures, including the skull, mandible, vertebral bodies, pelvis, hearts, and arteries.[25–33] By evaluating the accuracy of 3D printing in replicating patient anatomy, these studies[25–33] contribute to our understanding of the reliability and precision of 3D printed models in medical applications.
The accuracy of 3D printed models in replicating anatomical details is crucial for their reliability and usefulness in various applications. Recent researches [34–42] has shown that there is a minimal difference between 3D printed models and original source imaging data, regardless of the imaging modality used, such as CT, echocardiography, MRI, or rotational angiography. Comparisons between 3D printed models and original source images, based on current literature, have revealed a mean difference in dimensional measurements of less than 0.5 mm, indicating a high level of accuracy in the 3D models.
Furthermore, our study goes beyond the typical measurement of length to evaluate the accuracy of 3D printing models. We assessed the orientation and degree of specific anatomy structures by measuring the angle at ten specific anatomical locations, which enabled us to determine the orientation of the vascular branches. Our results show that the 3D printed models not only accurately replicated the length of the segmented model but also the orientation of the specific anatomical structure. We observed a mean difference in degree measurements of -0.298 ± 1.185° for model 1 and − 0.297 ± 1.362° for model 2, indicating good correlation between the 3D printed models and the segmented model. As a result, excellent correlations have been observed between different observers and measurement approaches, highlighting the reliability and consistency of 3D printed models in replicating patient anatomy across different imaging modalities.
The challenge of using this method in printing this model is the process in removing the supporting material without breaking the model. Vat polymerization is a printing method with three components including a high intensity light source, vat that holds a photo-curable liquid resin and controlling system which directs the light source to illuminate a specific area of resin. After a layer of specific area of resin is exposed to light and cured, the model is lowered or raised one layer of thickness to cover the previous printed layer. Each layer thickness is thus printed sequentially until the final layer is completed. After the printing is finished, post-processing to refine the model is necessary.[43] Post-processing of our printed model included removing the undesired support structures and the model is rinsed in a wash solution (isopropyl alcohol) to get rid of the liquid layer of resin. Subsequent steps including curing the model with ultraviolet light to enhance its mechanical properties.
Our study has certain limitations that need to be addressed. Firstly, unlike traditional animal models, our endovascular model does not allow for coil embolization with blood clotting. Secondly, a pulsatile simulator was not used in our study to simulate the native pressure and pulsatility of flowing blood. Furthermore, while our study focuses on creating an educational model to assess its accuracy and feasibility for education, there is a lack of designs and evaluation to determine the educational impact of this training model. Future studies can address this by designing a course or workshop to gather feedback from participants. Additionally, although our femoral pseudoaneurysm model is suitable for endovascular training, it is not currently applicable for training in other treatment methods such as ultrasound-guided compression or duplex-guided thrombin injection. Therefore, it is necessary to integrate this vascular model into an ultrasound-guided training model to encompass training in other treatment methods using ultrasound. Another limitation to consider is that our 3D printed model is single-use for endovascular embolization treatment training, which means that a new model would need to be printed for each training session. This can be costly, especially if multiple training sessions are required. Therefore, cost-effectiveness and sustainability of using 3D printed models for endovascular training should be further evaluated.