Applications of 3D Printing, Enhancing Precision Medicine

December 06, 2022 - The start of 3D printing in the 1980s has led to the progression and current uses of technology across various fields. The healthcare industry is no exception. Applications of 3D printing in healthcare are broad and are accompanied by a series of benefits and drawbacks. Focusing on the benefits, 3D printing in healthcare can enhance precision medicine, address supply chain issues, and expand educational opportunities. According to the Medical Device Network, some estimates project that 3D medical printing will be valued at $3.5 billion by 2025, with its 2016 value being significantly lower at $713.3 million.

3D Printing in Healthcare —The Basics

The basics of 3D printing involve developing a blueprint or map and then printing multiple layers of material until it forms a 3D product. Pew Trust defines 3D printing as “an additive manufacturing technique that creates three-dimensional objects by building successive layers of raw material such as metals, plastics, and ceramics. The objects are produced from a digital file, rendered from a magnetic resonance image (MRI) or a computer-aided design (CAD) drawing, which allows the manufacturer to easily make changes or adapt the product as desired.”

One of the first medically approved uses of 3D printing was in dental implants. Since early FDA approvals, multiple 3D printing technologies have been approved for more complex issues. According to American Hospital Association (AHA), only three hospitals had 3D printing facilities as of 2010. That number increased to 113 less than a decade later in 2019. Additionally, the AHA notes, “medical device manufacturers are making ever greater use of 3D printing to drive down costs and more consistently meet supply demands.”

Bioprinting

One of the first realms of 3D printing in medicine is bioprinting. While 3D printing can be done with a handful of different materials depending on the type of printer, a specific subset of 3D printing, bioprinting, uses live cells.

Unlike traditional 3D printing, bioprinting involves printing — or, more accurately, using a computer-guided pipette — layers of living cells, sometimes called bioink. These consecutive layers of live cells create laboratory-made artificial living tissues. It uses stem cells and a binding gel or collagen to scaffold cells together. In theory, a patient’s natural tissue would develop over the printed parts and replace the printed cells.

Benefits of Bioprinting

There are multiple applications of bioprinted tissues, such as research. In a laboratory setting, 3D-printed tissues can provide an ethical and safe way to mimic organs and test medications. In some cases, 3D printing can present a cheaper and more accessible alternative to human organ transplants. While the healthcare industry has yet to print and transplant a functional 3D-printed organ, many experts have high hopes for applications in this field. Using 3D printing to replace the current organ transplant system reduces costs, shortens the waitlist, and widens accessibility.

The AHA states that 3D printing has proven to be an asset in the medical community, particularly for developing organ models, bone and joint implants, and precision instruments.

Accurate Anatomical Models

Another application of 3D printing is the ability to develop accurate, detailed anatomical models to prepare medical personnel for complicated procedures. The ability to model and chart a plan before the start of a procedure can reduce the risk of complications, improve outcomes, and reduce spending.

Building anatomically accurate 3D models of organs involve multiple steps. First, a physician will begin by ordering medical imaging, such as an MRI, CT, X-ray, or another scan. Facilities can then take these scans, develop a 3D digital rendering, and transition it into a format that the 3D printer can read. The printer can then build up the model layer by layer.

“When printing different organs, various colored plastics can be used together to make a more complex model. If surgery is needed to remove a tumor, it can be printed using a different color than the organ it is growing in, so it is easier to see on the final model,” stated the Franklin Institute in a publication.

Applications and Benefits

The AHA notes that, in collaboration with the University of Virginia, Florida Atlantic University developed a robotic model of the human spine using 3D printing technology. The model was used to help surgeons predict the impact of specific surgical interventions. It found that the system was 100% accurate in predicting the candidacy of disc implants in five distinct postures.

A 2021 article published by Durham University states that 3D printing improves surgical success rates by allowing medical professionals to model surgical procedures before performing them on the patient. Durham University notes, “3D printed anatomical models were also useful when communicating the surgery details with the patient, helping to increase their confidence in the procedure.”

An additional study published in 2020 by Academic Radiology reported that 3D-printed surgical anatomical models for surgical guidance reduced the average procedure length by slightly more than an hour. According to Durham University, with 3D printing, surgeries that took between four and eight years were reduced by 1.5–2.5 hours. This had financial and practical benefits as hospitals could schedule more surgeries, bringing in additional revenue and shortening waitlists. Additionally, the savings amounted to an average of $3,720 per case.

Beyond assisting seasoned surgical professionals, building anatomical models can be a critical learning tool for medical students or residents when learning about particularly complex anatomies or procedures.

Implants and Medical Devices

Besides building anatomical models to prepare surgeons for surgery, 3D printing has also been used to customize surgical implants. A report published by Pew Trust states, “3D printing has enabled the production of customized prosthetic limbs, cranial implants, or orthopedic implants such as hips and knees.” Other current uses for 3D printing in medicine include manufacturing customizable, low-cost medical devices. The AHA states that forceps, clamps, hemostats, and retractors are commonly 3D printed.

Impacts and Benefits

Being able to modify surgical implants to be a perfect fit for each patient — in line with the ongoing era of precision medicine — is particularly advantageous. It allows the patient to adopt the implant better, minimizes the probability of rejection, and prevents complications.

In addition to improving surgical outcomes, 3D printing can reduce patient recovery time. The research highlighted by Durham University found that facilities utilizing 3D printing for anatomical models, surgical tools, and implants had a reduction in post-surgical complications and, in turn, reduced recovery times.

One significant benefit of 3D printing is that it can be easily modified. Since the printing is based on a digital design or model instead of a mold or other specialized equipment, it is relatively easy to adjust the model to create a better fit for the patient or provider.

A publication earlier this year in the Global Health Journal also notes that producing medical equipment via 3D printing can be less expensive and quicker than traditional production mechanisms.

Addressing Supply Chain Issues

The availability of 3D printing for medical devices and tools can also be used to minimize supply chain issues, as seen throughout the pandemic.

Another Pew Trust report states that 3D printing could be a stopgap solution for supply chain shortages in the medical industry. The organization notes that between February 15, 2020, and July 15, 2020, approximately 38 million face shields, 12 million nasal swabs, 2.5 million ear savers for masks, 241,000 mask components, and 116,000 ventilator parts were 3D printed, helping minimize some ongoing supply chain issues during the pandemic.

Future Considerations

It is clear that 3D printing has been an asset in the healthcare industry; however, it is not without its challenges. While this technology may save money down the line, the upfront costs of buying and maintaining the necessary device may be challenging for smaller healthcare facilities. In addition, how the FDA will regulate future 3D-printed medical devices, organs, or tissues becomes a concern for many industry leaders. While many hypothesize what directions the healthcare industry will take when it comes to 3D printing, others caution against too much optimism with so many unknowns at play.