Individual prefabricated titanium implants in reconstructive craniofacial surgery: clinical and technical aspects of the first 22 cases.

The reconstruction of craniofacial bone defects by intraoperative modeling of implants restricts the choice of material and its biocompatibility and also reduces the predictability of the aesthetic result. These shortcomings go hand in hand with a prolonged surgical procedure time and increased stress on the patient. In contrast, modern industrial computer-aided design and computer-aided manufacturing systems allow the prefabrication of titanium implants, i.e., individual computer-based three-dimensional models of the bone defect are generated after acquisition, transfer, and evaluation of helical computed tomographic data. Based on these data, the individual shape of the implant is designed using freeform-surfaces geometries and is fabricated by a numerically controlled milling machine in a direct fashion. The conical margins of this implant are designed with a precision of 0.25 mm to the borders of the defect, and the surface contours are generated harmonically to the nonaffected neighboring contours with a constant thickness of 1.5 mm. Individual constructions for fixation with the dimensions of microplates are integrated in this process if screw holes cannot be drilled in thin overlapping implant margins. The reconstruction of 22 posttraumatic, postoperative, or primary cranial and craniofacial defects measuring up to 18 cm was performed using this new method. Wound healing was uneventful in all but one case, although some of the patients had been operated on several times before. The result was always predictable and constant using this highly precise technique, and duration of surgery was reduced dramatically.