3D-printed models increase precision in head and neck tumor surgeries

The use of 3D printing in surgical planning continues to gain importance. A recent study by the Ohio State University Comprehensive Cancer Center – Arthur G. James Cancer Hospital and Richard J. Solove Research Institute shows that patient-specific, 3D-printed models can significantly improve precision in surgeries for head and neck tumors with bone involvement. According to the study, complete tumor removal with negative resection margins was achieved in 92 percent of procedures supported in this way.

“The precision of what we take out is critical to ensure we get the whole tumor, but not so much that we’re devastating the patient’s function in the long term and taking out things that don’t need to be removed,” said Kyle VanKoevering, MD, an otolaryngologist (head and neck surgeon) at the OSUCCC – James and medical director of the M4 Lab (Medical Modeling, Materials and Manufacturing Lab) within the Ohio State College of Engineering. “This 3D modeling being completely personalized to each patient is really helping improve the precision in the operating room.”

“This model is especially critical in cancers that have invaded bone, because tumor boundaries are often less visible or palpable. Our 3D models are built based on the patient’s actual tumor imaging, so it gives us a much better visual map at the patient’s bedside for removing the cancer as completely as possible while also sparing important structures and tissue to maintain function after surgery,” VanKoevering explained.

The study was based on 68 patients treated at the center. Of these, 37 underwent surgery using individually manufactured 3D models intraoperatively, based on CT and MRI data. These models accurately depict tumor boundaries and adjacent anatomical structures and serve as spatial references for surgeons during the operation. The comparison group of 31 patients was operated on without these aids.

“This really sets the stage for larger studies looking at how 3D modeling can enhance surgery planning and precision, not just in the field of head and neck cancer surgery but in other areas that involve bone and soft tissue, like orthopedics,” said Marquardt, who worked on this project as part of a focused medical school research year through the Pelotonia Scholars Program.

“Long term, our hope is that this work will enable other surgeons to use this technology across the country to help improve people’s lives and improve cancer outcomes,” said Marquardt.

The results were published in the scientific journal Oral Oncology. In the long term, the authors expect that comparable 3D-printing workflows will also become established in other surgical disciplines where complex bone and soft tissue structures require precise planning.