Prosthetic reconstruction of maxillo-facial defects by means of 3D optical reverse engineering and prototyping

Prosthetic reconstruction techniques of maxillofacial defects have gained increased interest in post oncological reconstruction and in congenital defect treatment, where both functional and the aesthetic characteristics of the prosthesis are crucial. We propose optical 3D acquisition, reverse engineering and rapid prototyping to virtually sculpture and fabricate facial prostheses in our study, a nose. A range camera is used to capture the patient’s face. Full coverage is obtained by using multi-view acquisition and alignment of point clouds. A number of "donor" organs to replace the lost one are acquired from healthy volunteers and virtually superimposed to the patient’s face to choose the best match to the face shape. Physical copies of the deformed face and of the ‘repaired’ face are obtained by means of rapid prototyping, differing in the defect zone. The two prototypes can be used either to directly cast the final prosthesis or to fabricate the positive was pattern. The main aspects of the process will be shown, with the results obtained in the nose prosthetic reconstruction, but with full applicability to other parts such as the eye and the ear.