3D Printing in Healthcare has transformed the way industries like healthcare, automotive, manufacturing, and design operate. 3-D labs have revolutionised preoperative planning, inter/intra-operative surgical guide planning, the post-processing time taken, patient communication, and overall treatment outcomes.

A 3-D lab in the healthcare system is a facility that is fully equipped with advanced imaging software, digital scanners, 3-D printers, and software systems that convert radiographic data like CT or MRI scans into detailed 3D printed models, patient-specific implants, cutting guides, etc. Thereby, they play a major role in optimising the surgical workflow through the integration of 3D Printing in Healthcare.

Richardson’s Face Hospital has a state-of-the-art 3D LAB which is equipped with the FORM 3B and FORM 4B equipment, known for making high-quality, accessible 3D Printing in Healthcare solutions.

In a world where 3-D printers are difficult to use, these printers are user-friendly and use the latest technology for printing fine and highly accurate models, making them a valuable advancement in 3D Printing in Healthcare.

They use software that has Stereolithography and Selective Laser Printing in their technology. Stereolithography uses a laser to cure liquid resin into solid layers, which is ideal for creating highly detailed and smooth prints, further contributing to innovations in 3D Printing in Healthcare.

Form Labs printers are well known for this stereolithography technology that is used in 3D Printing in Healthcare, especially for creating 3-D printed models for jaw surgery, aligners, dental crowns, skull models, and models of parts of the face.

These printers can create parts with incredible detail that give good precision, and the prints have a glass-like smooth finish. This technology also allows different types of resin, including flexible, durable, and specialized resin, making it highly versatile in advancing 3D Printing in Healthcare.

The 3D printers reduce the force that is exerted on prints during the curing process, which results in improved printing quality and faster print speed. This advancement in 3D Printing in Healthcare allows for fewer errors and imperfections with reduced printing time while maintaining high resolution.

It also enables better maintenance of the software and equipment, requiring less cleaning and finishing, further streamlining the overall workflow in 3D Printing in Healthcare.

Our 3D LAB has FORM 3B and 4B printers, which are great for small to medium-sized prints, and the FORM 3L printer, that is ideal for larger prints of 335 X 200 X 300 mm. This advanced setup in 3D Printing in Healthcare is especially useful for printing life-sized models of the entire skull!

The other equipment that is used to streamline the post-processing of 3-D printed parts in 3D Printing in Healthcare includes:

I. FORM WASH: The Form Wash is a machine that automatically cleans printed parts in isopropyl alcohol, making post-print cleanup easier.

II. FORM CURE: The Form Cure is a curing station that further hardens the prints for improved mechanical properties, ensuring higher precision and durability in 3D Printing in Healthcare.

III. NEMOSTUDIO: The Orthognathic virtual surgery planning, orthodontic clear aligners, and dental crowns planning are done using the NEMOSTUDIO software at our centre.

Orthognathic surgery, or jaw surgery, which is used for correcting dental and skeletal irregularities affecting facial appearance, bite function, and overall health, is regularly performed at our center. With the integration of 3D Printing in Healthcare, accurate planning becomes possible, ensuring better outcomes for these complex procedures.

Accurate planning is essential for the success of such surgeries, and 3D Printing in Healthcare plays a vital role in achieving precision and predictability.

Traditional methods of planning and simulation often involve manual measurements, 2D imaging, and trial and error, which can be time-consuming and prone to mistakes. 3D software planning now provides detailed 3D modeling, simulations, and integrated data management that enhance surgical outcomes, reduce risks, and improve the overall patient experience.

At Richardson’s Face Hospital, Nemo software is used to create highly detailed 3D models from patient CT scans and precise intraoral measurements. These 3D models help surgeons visualize the patient’s face from every angle, making it easier to plan for symmetry and functionality. Before performing any surgery, Nemo software allows simulation of different surgical approaches in a virtual environment—an advancement far beyond traditional methods where surgeons relied on sketches or trial and error.

Different approaches can be tested on the software based on the patient’s needs, with real-time visualization possible through multiple tools available. Surgeons, orthodontists, and other specialists can access and edit the 3D models in real time, improving communication and ensuring transparency so that everyone is aligned.

Surgeons can develop customized surgical plans detailing exactly where and how bones need to be repositioned. This reduces uncertainty during surgery, ensures precision with surgical guides, and optimizes both function and appearance. The software also helps measure differences between planned outcomes and actual post-surgery results, as well as bite changes, which can be discussed with patients—enhancing trust and transparency throughout the process.

Orthodontists use the software for planning the tooth movements for orthodontic treatment and thus delivering the clear aligners

Dentists use the software for planning dental crowns and dentures

IV. PREFORM: The software used for 3-D printing of jaw models is the Preform software. After virtual planning of the surgery on the NEMOFAB software, the printing of the models is executed through Preform.

This software generates 3-D printed surgical guides based on the virtual plan. With premade, customized guides, surgeries become more efficient, reducing the overall time spent in the operating room. These guides ensure that bones are repositioned with precision, optimizing both function and appearance.