CAD/CAM silicone auricular prosthesis with thermoformed stiffening insert

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CAD/CAM silicone auricular prosthesis with thermoformed stiffening insert

Journal Title: Archives of Materials Science and Engineering - Year 2017, Vol 1, Issue 83

Abstract

Purpose: Epitheses (facial prostheses) for large facial tissue defects manufacturedfrom silicones exhibit unsatisfactory rigidity and its stiffening is required, which createstechnological problems. Moreover, facial epitheses have to be replaced in a relatively shortperiod of use which creates a significant costs, often impossible to realize. The hypothesisof the study was that with use of additive manufacturing is possible to obtain the reusableform for thermoforming of the stiffening insert of auricular prosthesis and the mould whichallows multiple casting of silicone prosthesis with the insert.Design/methodology/approach: Manufacturing of the epithesis consisted of designingand manufacturing. In the first step, the auricular prosthesis and the stiffening insert weredesigned with use of engineering CAD software. In this first computer step, the split form forvacuum thermoforming of the stiffening insert and the split mould for casting of the siliconeear were designed. In the second step, additive printing was used for manufacturing thesplit and reusable model for vacuum thermoforming of the stiffening insert and the splitform of ear. In the third step, stiffening insert was made of thermoformed polyurethane sheetof 0.1 mm thick (Biolon, Dreve), where dental thermoforming machine (Drufosmart, Dreve)was used. In the fourth step, the stiffening insert was located in the mould and the ear wascasting of silicone.Findings: CAD/CAM of epitheses with stiffening insert for large tissues defect/loss wasproposed, where in case of re-producing, it required only thermoforming of insert andcasting silicone with use of the reusable models. Dental technician, in case of damage orloss of a forms, is not much involved in their creation.Research limitations/implications: Bond strength test between stiffening insert vs. softsilicone and manufacturing tolerance of epitheses have not been investigated.Practical implications: Method of casting in a negative form, despite the more timeconsumingwhen comparing with epithesis direct-printing, allows introducing a stiffeninginsert and performing a manual adjustment of margin shape and thickness. Method ofnegative form allows the use of a commercially available medical silicone without the needfor medical tests of a new printed materials.<br/><br/>

Authors and Affiliations

J. Żmudzki, M. Burzyński, G. Chladek, C. Krawczyk

Keywords

Face and ear epithesis Additive manufacturing Stiffening polyurethane insert

EP ID EP225460
DOI 10.5604/01.3001.0009.7539
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