Role of rapid prototyping in preoperative planning and patient-specific implant generation

Rapid Prototyping is making inroads into industries throughout the world. Other tools that act as "bridges" between many of the existing technologies are also becoming available. Stereolithography (SL) makes it possible to get an accurate physical part from computer-aided design (CAD) data into the hands of the designers in a relatively short period of time. Quick Cast technology (via SL) bridges the CAD and investment (lost wax) casting technologies by direct casting pattern generation-allowing the creation of castings without tooling. Surgicad, a CT-to-CAD conversion package, bridges the gap between CT imaging and the creation of a CAD database that can subsequently be used to create a physical part via SL. DePuy is utilizing these tools and technologies to facilitate the creation of patient-specific implants and preoperative surgical planning. Examples discussed include preoperative planning for surgical repair of an intercondylar fracture and a patient-specific femoral knee implant for revision surgery.