Study on How 3D Printer Process Parameters Can Be Optimized for Use in Orthopedics Fracture Classification and Surgical Planning

The revolutionary advance of 3D printing technology is currently being tested in many medical applications due to its potential for unique patient-specific treatments. In orthopedics, 3D printing of fracture models can be used to improve the accuracy of fracture identification and classification, as well as for preoperative planning and training. For 3D models to be useful in traumatology, it is necessary that they be available in the limited preoperative time from patient admission to surgery. Our study is based on the proximal ‘hip fractures’ from the Stavanger University Hospital case study. Treatment of this type of fracture occurs within 24 h. Various print parameters in the post-processing software, including layer height, print time, and material consumption, are examined, and evaluated to ensure the optimal balance between 3D print time and print quality. Wrapping and removal of unaffected parts and the reduction of the 3D model size greatly minimize the printing time. Reducing excess information and connecting cylinders decreases print time significantly while still giving enough detail without losing fracture morphology. Other parameters including whether the use of printers with multiple extruders leads to a reduction in printing time, since the distance and size of support structures significantly affect the printing time, needs to be investigated in further studies.