Fibula Free-Flap Reconstruction

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3DLP’s latest work with Satheesh Prabhu from the Churchill Hospital in Oxford for a patient’s mandible reconstruction highlighted the amazing power of using medical 3D printing techniques to improve patient outcomes. In this case, a complex fibula free flap surgical reconstruction, the patient’s fibula was removed and used to re-construct their jaw after tumour resection.

3D printed models were constructed and used to plan the surgery. 3D printed guides were constructed for the fibula and mandible to ensure accuracy, and subsequently a titanium 3D printed implant was permanently fixed to their mandible.

3DLP are proud to be able to provide their expert services and products to assist with improving surgical outcomes, and wish the patient a speedy recovery!

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Segementation & 3D Design

3D LifePrints received the CT scans of a patient suffering from osteoradionecrosis.

From the CT scan of the head of the patient, we reconstructed in 3D the anatomy of the patient: the maxilla, the mandible, the inferior alveolar nerve and the teeth.

We also get the angioscan of the leg and segmented the fibula with the vessels.

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The resection, determined by the surgeon, is virtually simulated (in red).


Using the patient’s own fibula, the reconstruction is then virtually performed, recreating the more anatomical shape possible.

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Patient-specific devices were designed based on the virtual simulation.

Three guides were designed: 2 resection guides for the mandible and a fibula guide.

A patient-specific reconstruction plate was designed and 3D printed.

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