Revolutionising surgery: 3D printing transforming maxillofacial care at UHDB
Patients undergoing reconstructive surgery at the Royal Derby Hospital are benefitting from pioneering 3D printing technology that is improving surgical outcomes, enhancing patient experiences and saving NHS resources - by creating model replicas of their skulls or jaw.
The University Hospitals of Derby and Burton (UHDB) Maxillofacial surgical team, based within the Head and Neck department at RDH, is harnessing the power of 3D printing to drive advancements in patient care.
Maxillofacial surgery deals with conditions involving the head, neck, jaw, and face – particularly intricate areas of the body which often makes procedures challenging and extensive. Thanks to 3D printing, surgeons at UHDB can now develop highly detailed replicas of a patient’s unique anatomy based on CT scans - such as where a tumour may be located within their skull - to plan and rehearse surgeries in advance, allowing them to prepare for complex procedures with unparalleled accuracy. This level of precision means fewer unexpected complications, reduced operating times, and better overall outcomes for patients.
By integrating this innovative technology into their practice, surgeons are also giving the patients as much information about the nature of their condition, and why their surgery is required, with the opportunity to provide them with a visual demonstration of what their operation entails
Mr Keith Jones, Consultant Maxillofacial Surgeon at UHDB - who has seen first-hand the difference this technology is making - said that 3D printing has “completely revolutionised" how the team approach complex maxillofacial procedures.
He explained: “These models allow us to practise surgeries, refine our techniques, and anticipate challenges before we even enter the theatre. That means we’re working more efficiently, with a higher degree of accuracy, and ultimately achieving better results for our patients.”
Beyond surgical planning and informing the patients in advance of their surgery, the technology is also being used to produce bespoke implants, plates and surgical guides, tailored specifically to each patient. This personalised approach is helping to reduce complications and speed up recovery times, ensuring patients can return to their daily lives more quickly.
Keith said: “Our focus is always on the patient. By tailoring procedures to their unique needs, we’re reducing complications, improving outcomes, and making sure they receive the best possible care.”
The introduction of 3D printing aligns with our wider strategy of embracing technological innovation to improve upon, and deliver outstanding care. By making procedures more efficient, reducing the length of surgeries, and minimising hospital stays, this approach is not only enhancing patient experiences but also easing pressure on NHS resources and finances.
Mark Lacey, Divisional Director of Surgery at UHDB, praised the impact of 3D printing on the Trust’s surgical services. He said: “This technology has been a real game-changer for us and for our patients.
"Our first priority will always be providing outstanding care, and 3D printing is helping us achieve that by enabling a significantly better aesthetic outcome for our patients who undergo extensive facial and reconstructive surgery, often as a treatment for cancer.
"At the same time, we’re making better use of our resources, which are critical as the NHS faces increasing demands. The work being done by the team is something we're incredibly proud of."
One recent patient case illustrated just how transformative this technology can be. A complex jaw reconstruction surgery was planned and rehearsed using a patient-specific 3D model, allowing the surgical team to work with complete confidence on the day of the operation, while allowing the team to explain to the patient, as Mr Jones puts it, "that his 'little bit of swelling' was an extensive tumour" which required such extensive surgery.
The procedure was completed more efficiently, with a high degree of accuracy, and the patient experienced a smoother recovery as a result.
Mr Jones said: "For the patient, it wasn’t just about the physical outcome - it was about restoring their confidence and quality of life. That’s why this technology is so important. It’s not just changing how we work as surgeons - it’s changing what’s possible for our patients.”
As well as revolutionising current practice, 3D printing is also shaping the future of surgical care at UHDB by inspiring the next generation of medical professionals. The technology is now being incorporated into training programmes, giving doctors in training and medical students hands-on experience with the tools that are set to define the future of surgery.
“We’re helping to normalise innovation", Mr Jones added. "By integrating 3D printing into training, we’re preparing the future workforce to continue improving care and exploring new possibilities. This is the direction surgery is heading in, and we want to make sure we’re leading the way.”
The introduction of 3D printing technology is a shining example of how, by combining clinical expertise with cutting-edge tools, the Trust is working innovatively to design more effective treatments and drive better health outcomes.
Keith summarised the innovations by saying: “At the heart of this is the patient. Everything we do is about improving their experience and ensuring they receive the highest standard of care. 3D printing has opened up possibilities we couldn’t have imagined just a few years ago, and it’s exciting to think about where it could take us next.”