Assessing 3-D Printing in Hip Replacement Surgical Planning.

Purpose: To evaluate the accuracy of 3-D printed models of the femoral head based on preoperative computed tomography (CT) images. Other goals were to compare the cartilage thickness of bony specimen to the printed models and calculate the standard deviation between 3-D printed models based on CT images and laser scan models.

Methods: This retrospective study analyzed 10 patients who underwent preoperative CT imaging and hip replacement. Preoperative femoral head 3-D printed models were produced from CT images. Bony specimens were collected from surgical operations and scanned using CT and 3-D laser scanning, and cartilage thickness subsequently was measured by histological analysis. Comparisons of printed models based on CT images and printed models based on 3-D laser scanning were performed by overlapping their external surfaces using dedicated software and the standard deviation was calculated.

Results: The average standard deviation between the bony specimen 3-D models and preoperative 3-D printed CT femoral head models was 0.651 mm. The cartilage was approximately 1.487 mm thick.

Discussion: The comparison between preoperative CT image-based 3-D models and the postoperative bony specimen-based models permitted evaluation of the accuracy of preoperative CT image-based 3-D printed models. Cartilage thickness was estimated indirectly by comparing models obtained by CT and laser scanning, and it was related to the calculated standard deviation to overcome the cartilage detection limit of CT. This study shows how each step can generate accuracy errors on the final 3-D printed model. A repeatable and sustainable workflow for creating accurate and reproducible 3-D printed models could overcome this issue. Moreover, orthopedic surgeons should be aware of 3-D printed model precision in clinical practice.

Conclusions: This study provides encouraging results on the accuracy of 3-D printed models for surgical planning.