Reverse engineering and CAD/CAM application in the design of maxillofacial prosthesis

This research study describes the design and fabrication of three different facial prostheses (ocular, obturator, and auricular). The procedure is divided into three stages: Reverse Engineering (RE), CAD design, and CAM manufacture. A portable Three-Dimensional (3D) scanner is used to collect patient data during reverse engineering. CAD refers to the 3D reconstruction of a bespoke prosthesis, including anatomy and mold design, while CAM refers to the production of the prosthesis utilizing 3D printing technology. The defect is reconstructed by mirroring the healthy side and using it as a reference to cover it entirely. The rebuilt models are 3D printed in biocompatible materials for the eye and obturator, which were used on patients for trials with subsequent mould preparation which were 3D printed in non-biocompatible material. In addition, a comparison of moulds created using traditional CAD/CAM procedures for auricular prosthetics is also presented. Mirroring the healthy side has been proven to be the gold standard for designing prostheses and medical-grade silicon is the best poring material. Finally, the research work shows that RE for recording defective regions followed by its design and using 3D printing technology has been proven a useful technique for reducing time and increasing the quality of the final product. CAD allows for almost unlimited forms and sizes of digitized noses that may be tested on the patient's digitized face. Although it seems costly in terms of money, it does minimize the number of visits and chairside time for patients.