Digital image capture and rapid prototyping of the maxillofacial defect.

In order to restore an extraoral maxillofacial defect, a moulage impression is commonly made with traditional impression materials. This technique has some disadvantages, including distortion of the site due to the weight of the impression material, changes in tissue location with modifications of the patient position, and the length of time and discomfort for the patient due to the impression procedure and materials used. The use of the commercially available 3dMDface™ System creates 3D images of soft tissues to form an anatomically accurate 3D surface image. Rapid prototyping converts the virtual designs from the 3dMDface™ System into a physical model by converting the data to a ZPrint (ZPR) CAD format file and a stereolithography (STL) file. The data, in conjunction with a Zprinter(®) 450 or a Stereolithography Apparatus (SLA), can be used to fabricate a model for prosthesis fabrication, without the disadvantages of the standard moulage technique. This article reviews this technique and how it can be applied to maxillofacial prosthetics.