3D printing in medical use: New implantation system developed for orbital fractures

A new procedure for the treatment of orbital floor fractures could significantly reduce the risks of previous operations. Dr. Moritz Burger, a doctoral student at the Laboratory for Medical Devices at OTH Regensburg, has developed an implantation system that enables minimally invasive procedures. The method is based on an approach through the nose and maxillary sinus instead of surgically opening the lower eyelid, as was previously the case. The conventional method carries considerable risks of complications, including possible injury to the optic nerve.

Fractures of the orbital floor often occur as a result of falls or accidents, especially in older people. In severe cases, surgical treatment is unavoidable. Prof. Dr. med. Thomas Kühnel from Regensburg University Hospital had already developed a concept for a minimally invasive procedure, but a suitable implant had not yet been found. As part of a project funded by the Bavarian Research Foundation, Burger designed both the implant and the associated implantation system.

“Prof. Dr. Kühnel initially let me watch operations,” says Burger. “This allowed me to see for myself what problems there are and what requirements an implant has to meet – for patients, but also for doctors as users.”

The development was based on precise data from clinical CT scans. A 3D-printed skull was used to adapt the design in detail. The implant is designed to be inserted through a 12 millimeter opening. It unfolds mechanically at the fracture site and adapts to the individual anatomy. Together with Gerresheimer Regensburg GmbH, a prototype suitable for series production was manufactured.

The new system promises to minimize complications and simplify treatment.

Prof. Dr.-Ing. Thomas Schratzenstaller heads the laboratory for medical devices and was Moritz Burger’s doctoral supervisor. “We would like to bring the new implantation system onto the market together with industrial partners and thus replace the previous method. However, approval can take up to five years.”