Fabrication of three-dimensional scan-to-print ear model for microtia reconstruction

Background: Microtia is a congenital deformity of the external ear that occurs in 1 of every 5000 births. Microtia reconstruction using traditional two-dimensional templates does not provide highly detailed ear shapes. Here, we describe the feasibility of using a three-dimensional (3D) ear model as a reference. Materials and methods: Seven children aged from 11 to 16 (6 grade III and 1 grade II microtia) were recruited from Seoul National University Children's Hospital, Korea. We generated 3Decomputer-aided design models of each patient's ear by performing 3D laser scanning for a mirror-transformed cast of their normal ear. The 3D-printed ear model was used in microtia reconstruction surgery following the Nagata technique, and its shape was compared with the casted ear model. Results: One patient experienced irritation caused by accidently pouring resin into the external auditory meatus, and another had minor skin necrosis; both complications were successfully treated. The average percentage differences of the superior, inferior, anterior, posterior, and lateral views between the casted and 3D-printed ear models were 1.17%, 1.48%, 1.64%, 1.80%, and 5.44%, respectively (average: 2.31%), where the difference between the casted ear models and traditional two-dimensional templates were 16.03% in average. Conclusions: Our results show that simple microtia reconstruction can be performed using 3D ear models. The 3D-printed ear models of each patient were consistent and accurately represented the thickness, depth, and height of the normal ear. The availability of the 3D-printed ear model in the operating room reduced the amount of unnecessary work during surgery. (C) 2016 Elsevier Inc. All rights reserved.