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10 Use of Three-Dimensional Technology for Virtual Surgical Planning in Oral…
https://t.me/medicina_free
Computed tomography (CT) scans and Cone Beam CT (CBCT) both have good
spatial resolution, whereas Magnetic Resonance Imaging (MRI) has higher contrast resolution. MRI is superior to computed tomography in determining soft
tissue alterations; however, its ability to provide high-resolution images of bone
can be limited [2]. For this reason, CT scans are widely used in oral and maxillofacial surgery cases since they often involve hard tissue interventions. CBCT
offers high spatial resolution with less radiation exposure compared to CT scans
but has poor contrast resolution [3]. The disadvantage of the previous imaging
modalities is the inability to capture very ne details of teeth structures such as
the ridges and grooves which might be necessary when constructing, for example, occlusal splints for orthognathic surgery or dental implant surgical guides.
3-dimensional (3D) intraoral laser scanning (IOS) is used to provide the ne
details necessary to facilitate procedures when meticulous details are necessary.
IOS creates images that are stored as stereolithography le (STL) then undergoes
Digital Imaging and Communications in Medicine (DICOM) encapsulation. This
process produces a reliable 3D image that can be used to create an accurate virtual representation of an object, that is, dentition and gingiva. The high accuracy
of virtual surgical planning (VSP) design and translation through cutting guides
and hardware have been thoroughly studied and established in the literature [4–
7]. In addition, this method to plan surgery has been shown to reduce operative
time and minimize complications in all its applications [8–11].
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Imaging Modalities—Soft Tissue Considerations
VSP for maxillofacial bony reconstruction is often done in conjunction with imaging of related soft tissue structures to obtain adequate coverage of the ablative
defect. With respect to soft tissue reconstruction, head and neck surgeons predominantly choose between two approaches: pedicled aps and free aps. The bula and
radial forearm regions are among the most common osteomusculocutaneous free
ap donor sites to be harvested with a skin island [12]. Adequate perfusion of the
tissue is necessary for these aps to be viable. Indeed, perfusion to the donor region
should be assessed preoperatively, with methods depending on the chosen site. For
example, CT-angiography can be used to conrm the presence of three-vessel runoff in the lower leg for bula free aps. Upon visualizing the perforators from the
peroneal artery, bula osteotomies can be planned to obtain a long pedicle and reliable cutaneous portion [13].
Additionally, the anterolateral thigh (ALT) is the workhorse fasciocutaneous ap
for when soft tissue bulk is needed. Emerging technologies such as handheld thermal imaging provide a novel intraoperative modality for perforator identication,
negating the need for conventional Doppler imaging [14]. Such devices supplement
the surgical armamentarium, providing greater condence in the design and perfusion of the skin paddle.

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S. A. D. Al Azri et al.
Data Acquisition
Appropriate use of the previously discussed imaging modalities is pertinent to a
successful virtual surgical plan when using custom devices. Any anatomical inaccuracies made during data acquisition can compromise the nal surgical outcome.
Most procedures in oral and maxillofacial surgery involving bony reconstruction
require CT imaging. An image slice thickness of 1mm is an acceptable compromise
between high resolution and minimal radiation exposure for the patient [15].
To facilitate virtual modeling and editing between various software and various
clinical applications, CT data is stored in a DICOM format. Conversion of this format to a 3D object le for use in VSP requires virtual stacking of each radiographic
section. Proprietary software such as Materialize Mimics (Materialize, Leuven,
Belgium) can be used to build a virtual model. If required, the model can be 3D
printed at this stage. However, where editing, rendering, and analysis of the virtual
model is required, computer-assisted design (CAD) software should be employed.
Such commercially available software includes Geomagic® Freeform® PLUS (3D
Systems, Rock Hill, SC, USA) and Proplan (Materialize, Leuven, Belgium). The
ultimate purpose of these software is to nalize the surgical plan and export the
model into additional programs for fabrication of cutting guides or other operative
hardware.
Optical scanning is another technology that has proven to be high-yield with
regards to data acquisition for VSP in maxillofacial procedures involving dentition.
Occlusion-driven, reverse VSP provides the optimal workow for preprosthetic
considerations. For example, the Chris O’Brien Lifehouse Cancer Center digital
workow for mandible reconstruction begins with the optical scanning of an ideal
denture wax-up positioned onto a 3D printed model of the reconstructed bone [16].
This data is superimposed with scans of the existing teeth, denture wax-up, planned
reconstruction, dental implants, and native bone using CAD software such as 3ds
®
Max
(Autodesk®, San Rafael, California). This model can then be 3D printed for
preoperative bending of an off-the-shelf titanium xation plate if needed.
Alternatively, the data obtained from the virtual surgery workow can be used to
fabricate customized hardware [17]. Registration of the xation plate and any necessary screws can again be done using optical scanning and superimposition onto
the virtual plan.
Applications
Orthognathic
Virtual surgical planning (VSP) has revolutionized orthognathic surgery planning.
It provides precise and predictable movements of the maxillofacial skeleton compared to conventional surgical planning (CSP), which is attributed to numerous

10 Use of Three-Dimensional Technology for Virtual Surgical Planning in Oral…
https://t.me/medicina_free
opportunities for error and inaccuracies [18]. Combining different imaging modalities and intraoral laser scanning (IOS) for virtual surgical planning has replaced the
traditional orthognathic workup and need for dental impressions, and face bow
measurements with the added benet of reduced inaccuracies and costs [6, 18].
Jones and colleagues [6] found that the use of patient-specic cutting guides and
implants constructed with VSP provide more accurate maxillary repositioning during bimaxillary surgery than the use of an interim splint constructed by traditional
methods. Resnick and colleagues [19] further examined operative time and cost of
bimaxillary surgeries of 43 patients to show that operative time and costs were signicantly higher in all the patients with conventional orthognathic workup compared with VSP surgeries. These ndings are signicant because prolonged
operative time is closely correlated with increased postoperative complications
[20]. VSP has made orthognathic surgeries more accurate and efcient when compared to conventional surgical planning [21, 22]. A standard orthognathic VSP
workow is outlined in Fig.10.2.
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Pathology andReconstruction
Oncologic resection and reconstruction of maxillofacial defects has seen an
immense benet from 3D technology such as VSP. Throughout the digital workow, 3D technology provides the ability to accurately visualize the pathology and
more condently plan the required osteotomies (Fig.10.3). Particularly, with respect
to areas of the midface, where direct visualization of some pathologies can be hard
to obtain, that is, within the paranasal sinuses and nasal cavity. Using existing imaging techniques, patient-specic cutting guide designs can be optimized to prevent
inadvertent injury to vital structures, such as at the skull base while maintaining safe
oncologic margins.
Additionally, immediate intraoperative feedback can be achieved through the
integration of both live 3D navigation and VSP together. Osteotomies made using
these modalities in anatomical models have been more accurate in distance, pitch,
and roll [23].
Clinically, the margins for surgical resection of lesions can be difcult to discern,
such as in osteoradionecrosis (ORN). In these patients, dosimetry-guided VSP has
emerged as a new technique that can be used to plan optimal osteotomies, with the
goal of obtaining healthy native bone margins. By superimposing previously delivered radiotherapy dosimetry data onto the corresponding virtual mandible, Jenkins
and colleagues [24] have been able to use IPS® planning software (KLS Martin IPS
Service UK Ltd) to integrate a radiation “heat-map” of the affected mandible with
CT data to redene the necessary margins. This additional planning stage is important where the mandible has received >60Gy of radiation, placing the native bone at
higher risk of ORN [25].
The recent adoption of Titanium Milling and Selective Laser Melting (SLM)
manufacturing techniques in high-volume surgical centers has heralded a shift from

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Data Collection
Obtain intraoral and extraoral photographs with a standardized background (white or blue
1.
wall)
Fabricate stone or digital models (intraoral scans) in reproducible centric occlusion
2.
Deliver data to processing center for rendering (digital upload or physical media)
3.
Often stone casts are sent with digital scans as a reference mark to the final occlusion
4.
Though optional, casts are particular helpful in segmental surgical planning
5.
Pre-Planning
Stone models are superimposed with CT images to check for inaccuracies
1.
Once verified, scans are imported into digital cephalometric program such as Dolphin
2.
Cephalometric points and planned osteotomies are imported into the digitized facial skeleton
3.
Coordinate planning session with surgeon, engineer, and possibly orthodontist
4.
Planning Session (Digital Model Surgery)
First, assess for maxillary cant and maxillary dental and facial midline (refer to clinical photos)
1.
Le Fort osteotomy is virtually placed based on anatomical landmarks (i.e. canine apices)
2.
3.
If required, interdental maxillary osteotomies can be placed at this time
Cephalometric measurements are placed in the lateral view (SNA, SNB, maxillary depth, etc.)
4.
Determine vertical position of maxilla based on clinical photos
5.
6.
Once the maxilla is in ideal position, the mandible can be placed into class I canine occlusion
7.
The type of mandible osteotomy (SSO vs. VRO) should be made known to all planning
members
8.
A genioplasty can be virtually executed at this point, if necessary
S. A. D. Al Azri et al.
Osteotomy guides are typically based on occlusal surfaces for stability
1.
Occlusal splints are fabricated to guide the final position of the osteotomy segments
2.
Stereolithic models allow evaluation of critical landmarks (i.e. neurovascular bundle)
3.
Fig. 10.2 Orthognathic surgery workow. SNA Sella Nasion A, SNB Sella Nasion B, SSO sagittal
split osteotomy, VRO vertical ramus osteotomy. (Reproduced with permission from Hua, Jack etal.
“Virtual Surgical Planning in Oral and Maxillofacial Surgery.” Oral and maxillofacial surgery
clinics of North America vol. 31,4 (2019): 519–530. doi:10.1016/j.coms.2019.07.01)
off-the-shelf xation plates to personalized patient-specic plates. As a result of
VSP, titanium plates can be purpose-built for specic cases, taking care to avoid any
vital structures detected on imaging. Milled mandibular plates are manufactured
from a titanium alloy block, for which a computer-assisted design (CAD) is generated using a digital contour of the reconstructed virtual mandible. Conversely, SLM
Manufacturing Considerations

10 Use of Three-Dimensional Technology for Virtual Surgical Planning in Oral…
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197
Fig. 10.3 Resection
margins are determined
during virtual surgical
planning. Threedimensional (3D) objects
are created from computed
tomography (CT) and cone
beam scan images. (a) 3D
reconstructed coronal view
of myxoma in the left
mandible. Area of
resection highlighted in
red. (b) 3D reconstructed
Sagittal view of myxoma
in the left mandible. Area
of resection highlighted in
red. (Courtesy of DePuy
Synthes/Materialise)
a
b
manufacturing of personalized plates involves a type of 3D printing where titanium
particles are melted and fused together in the desired fashion. Because of their exact
manufacturing technique, personalized plates may provide a better biomechanical
outcome compared to conventional plates that undergo material deformation during
bending [26]. Personalized plates also allow for further modications to be made.
Smith and colleagues [27] have introduced an additional tab to their SLM plates that
wraps around the lateral mandibular segment for additional xation (Fig.10.4).
When planned correctly, the temporary xation holes of each cutting guide can also
be repurposed for subsequent parts of the reconstruction such as permanent xation
and dental implant placement, taking care to avoid any vital neurovascular structures. Additionally, adequate occlusion for oral rehabilitation can be obtained
through using VSP for precise implant placement, preventing buccal or lingual rotation of the implant and osseous ap [28].
A relatively novel application of this technology has been the 3D printing of
single-unit titanium plates for vascularized maxillary reconstruction (Fig. 10.5).
The University of Texas Health Sciences Center at Houston (UTHealth) were the

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a
https://t.me/medicina_free
Fig. 10.4 Virtually
constructed threedimensional (3D) printed
bone plate with added
registration tables. (a)
Axial view of 3D
reconstructed mandible
with bula segments and
personalized plate. Fibula
segments are highlighted in
green and yellow. Arrows
denote the registration
tables. (b) Lateral view of
3D reconstructed
mandible. Arrows denote
the registration tabs.
(Courtesy of DePuy
Synthes/Materialise)
S. A. D. Al Azri et al.
b
rst reported surgical team to use a customized single-unit system for this purpose
(Synthes PSI TRUMATCH CMF Solutions; Depuy Synthes CMF, West Chester,
PA) [29]. The primary goal of using VSP in maxillary cases is to preoperatively
design a specic plate for the neomaxilla that maximizes contact with the thickest
portion of the remaining healthy midface bone. This enables engagement of an optimal bilateral zygomaticomaxillary buttress (Fig.10.6). The secondary goal of these
custom plates is to minimize the plate prole, thus preventing extrusion out of the
soft tissue. Ultimately, customized plates designed with VSP provide a comprehensive and efcient approach to maxillary reconstruction.
Using VSP has also facilitated accurate localization and reconstruction of soft
tissue structures within bone (Fig.10.7).
For the maxillofacial cancer patient, oral health-related quality of life can be
negatively impacted by problems related to chewing, esthetics, and speech that arise

10 Use of Three-Dimensional Technology for Virtual Surgical Planning in Oral…
https://t.me/medicina_free
Fig. 10.5 Virtually
constructed threedimensional (3D) printing
single unit titanium plate
for vascularized maxillary
reconstruction. Coronal
view of personalized
hardware. Fibula segments
are highlighted in purple,
yellow, and green.
(Courtesy of DePuy
Synthes/Materialise)
199
from missing teeth. Therefore, the paradigm of occlusion-driven planning for
implant reconstruction and prosthetics has dominated head and neck surgery in
recent years. For example, following the virtual design of a neomandible using bular reconstruction, the occlusion can be superimposed to be coincident with the
opposing arch. This will guide the placement of dental implants to support a xed
or removable prosthesis.
Although the bula remains the workhorse ap for reconstructing composite
maxillofacial defects, alternative approaches continue to be developed. In 2017,
Gellrich and colleagues [30] were the rst to describe a novel patient-specic titanium framework implant system used for the oral rehabilitation of patients with
severe alveolar atrophy or resected maxilla. Using the aforementioned SLM technology, a patient-specic titanium scaffold and implant construct is engineered following digital prosthetic assessment and planning. To obtain this virtual plan, the
surgeon must obtain a stereolithographic (STL) le of the future denture using an
optical scanner before digitally fusing that data with the patients’ CT scans and
planning the reconstruction starting at the occlusion [30]. These processes can be
done in-house if needed, using a planning tool such as iPlan® (Brainlab®,
Feldkirchen, Germany) and a computer-aided design software such as Geomagic®

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S. A. D. Al Azri et al.
ab
Fig. 10.6 The three-dimensional (3D) printed single unit maxillary plate xed to the bula segments. (a) After harvest/prior to inset to the maxilla. (b) Maxillary construct with custom plate,
installed into recipient site, after inset
Freeform® PLUS (3D Systems, Rock Hill, SC, USA). By using this workow,
Spalthoff and colleagues [31] demonstrated that the dental rehabilitation of patients
using the novel implant system was comparable to conventional rehabilitation without digital planning. Therefore, computerized planning of these prosthetics and
reverse engineering of the implant scaffold provides a promising alternative to conventional soft and hard tissue reconstruction following ablative surgery.
However, development of the plan and manufacturing of guides necessitates extra
time. Most centers do not have the resources to complete a full workow in- house
and must outsource this to an external collaborator. Despite being criticized for
potentially delaying surgery, incorporating the VSP workow has not been shown to
compromise oncologic outcome and has shown a statistically signicant reduction in
operating time between 30 and 90mins including free ap reconstruction [32].

10 Use of Three-Dimensional Technology for Virtual Surgical Planning in Oral…
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201
ac
d
b
Fig. 10.7 (a) Integration of cutting slots in the cutting guide to assist in lateral corticotomy window and localize the inferior alveolar nerve. (Courtesy of KLS Martin Group). Arrow denotes
groove for the location of the inferior alveolar nerve. (b) Close up of the cutting guide and osteotomy window. (c) Inferior alveolar nerve lateralization as assisted by the integrated slots in the
cutting guide followed by (d). Reconstruction with nerve graft
Jaw inaDay
Placement of osseointegrated dental implants primarily in vascularized free ap
was rst described in 1989 by Urken etal. [33]. The immediate placement of dental
implants into the neomandible, while it is still at the donor site, has the advantage of
access to ensure accurate placement of the dental implant, adequate assessment of
ridge thickness and height, and less stages involved as compared to implant placement after bone and soft-tissue healing, which ultimately means earlier dental rehabilitation [34]. These dental implants were restored traditionally in collaboration

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with dental laboratories, which resulted in unavoidable delays and patient dissatisfaction. Hutchison and Dawood rst performed immediate loading of dental
implants placed in reconstructed microvascular scapula ap in 2007 [35]. This has
further evolved to in-house creation of 3D printed dental prosthesis, which has been
described and popularized recently with the advent of point-of-care threedimensional (3D) printing. The in-house 3D printed prosthesis required a shorter
time to be constructed, and the cost of fabrication was less compared to laboratoryfabricated prostheses [36]. Case selection is very important to predict the soft-tissue
needs for composite defects. VSP revolutionized osteocutaneous vascularized free
ap planning in terms of ideal positioning in the maxillofacial skeleton and taking
into account the occlusal relationships which subsequently can be used for ideal
position of dental implants using the same cutting guides. The digital data required
for planning immediate dental implants on bula include: CBCT, CT scan of the
bula with 1mm cuts, and digital model of the existing teeth, which can be obtained
by intraoral scanner, optical dental scan, or CBCT of polyvinyl siloxane impression.
The digital data is then processed and used by commercially available planning
software to plan the immediate prosthesis. The plan is then executed and used to 3D
print the nal prosthesis using a commercially available 3D printer. Other supplies
such as alcohol bath and curing ovens are also required for post-printing processing
and nalization of the restoration. The concept of jaw in a day is combining multiple advances in planning, accuracy, and the ability to fabricate prosthesis to be available on the day of surgery [37] (Fig.10.8).
S. A. D. Al Azri et al.
Future Directions
Although VSP can improve the outcomes of many complex and technically challenging surgeries, it has limitations that are currently beyond the surgeons’ control.
Barriers to the effective use of VSP are associated with the inherent delays associated with current manufacturing capabilities and human error. On average, the
authors’ experience with the turnover between VSP planning session to delivery of
implant/guides can range between 7 and 14days for pre-bent and milled hardware,
whereas 3D-printed plates and laser-sintered hardware can be produced in
14–17days. These limitations are due to the logistics involved in the processing,
quality control, and transportation of the prostheses. Several options are available to
reduce the turnaround time, through the use of in ofce or institutional 3D printers
and resources. Surgeons have become their own engineer to design and facilitate the
planning process and create acrylic guides; we are still limited by the ability to print
or mill implants and hardware. Data sets can be created faster and forwarded to
manufacturing sites to create the implants and hardware. Virtual surgical planning
will continue to improve, and methods to acquire and process patient data will
become more rened. Meticulous attention to each step is necessary to ensure a
positive outcome. Future trends will likely include widespread availability of 3D
printing and manufacturing technology and an increasing number of surgeons taking on the role of the engineer.
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