Patient-Specific 3D-Printed Cutting and Repositioning Guide for Mandibular Tumor Resection: Surgical Design and Validation

Abstract

Mandibular tumor resection poses significant surgical challenges in terms of achieving precision and restoring anatomical symmetry. Virtual surgical planning (VSP) combined with 3D printing offers a promising solution through the use of patient-specific guides. A workflow integrating CBCT imaging, segmentation using Mimics and 3-Matic, and design of patient-specific cutting and repositioning guides was developed. A 52 years old patient with squamous cell carcinoma was treated using this approach, and the guides were fabricated from PLA with dimensions tailored to the patient and case specific dimentions. The cutting guide ensured tumor-free margins while conserving as much as possible of healthy bone. The repositioning guide restored anatomical alignment with high accuracy. Guides were lightweight, very precisely adapted, and demonstrated surgical feasibility and reproducibility. This study presents a streamlined, low-cost approach to mandibular tumor resection using 3D-printed guides. The workflow allows for reproducible surgical outcomes without the need for intraoperative navigation.