Cancer Patient Uses 3D Printing Technology to Rebuild a Nose on the Forearm
In 2022 a French team at the Claude Regaud institute and Toulouse University Hospital transplanted a nose rebuilt on a patient's forearm. A cancer patient uses 3D printing to plan that reconstruction. This page explains the workflow for engineers who build the models, guides and implants behind it.
What the 2022 Nose Transplant Actually Involved
The patient lost part of her nose to nasal cancer in 2011. Standard reconstruction had already been tried more than once, and the results did not hold well enough. In 2022, clinicians in France planned a different route: raise a flap on the forearm, shape it into a nose, let it mature with a blood supply of its own, then transplant it to the face.
This is where the cancer patient uses 3D printing part of the story. A 3D printed model of the patient's skull and soft tissue gave the surgical team a physical reference for the flap geometry and the position of the implant that would support it. The printing step did not create the nose itself. It made the plan measurable before anyone cut.
The distinction matters for engineers. A printed anatomical model is a planning and communication tool. It sits in the same family as a printed surgical guide or a drill template. The load-bearing part, in this case the support structure under the skin, is usually machined or molded from a validated material with traceable stock.
Teams that read the case as a materials breakthrough miss the interesting part. The hard work was registration: turning CT data into a model that matches the patient, then repeating that match in the operating room. That is a dimensional problem, and it is the same problem we solve daily on the shop floor.
- 12011Part of the nose removed after nasal cancer
- 22022Forearm flap matured, then transplanted
- 3Role of 3D printingAnatomical model and surgical planning
- 4Load-bearing partsMachined or molded, not printed
From CT Scan to a Physical Model
The chain starts with a CT or MRI volume. Bone and skin are separated by density thresholds, then the surfaces are reconstructed as a triangle mesh. At this point the file is usually too rough to mill or print cleanly, so it needs smoothing, hole filling and a remesh that keeps the anatomical landmarks intact.
Next comes the scale check. A model printed at 100 percent is only useful if the printer and the material shrink predictably. For a face, a 1 percent error is visible. We verify by measuring known distances on the raw scan and on the finished model, then correcting the build file for the offset.
The output format depends on the process. Stereolithography and material jetting give fine surface detail for soft tissue. Fused deposition is cheaper and fine for a rough handling model. If the model has to hold a threaded insert or a metal guide, print it in two pieces and machine the mating feature.
One practical point. Keep the scan data, the segmentation settings and the correction factor in one folder with the part number. When a surgeon asks for a revision two weeks later, you can rebuild the same model instead of re-segmenting from scratch.
- 1SegmentSeparate bone and soft tissue by density
- 2RemeshSmooth surfaces, keep landmarks
- 3CorrectCompensate for shrink per process
- 4ArchiveStore scan, settings and correction factor
Choosing a Process for Medical Models and Guides
Rough guide only. Final choice depends on sterilization route and the number of parts needed.
| Process | Best for | Watch out for |
|---|---|---|
| SLA resin | Anatomical models, drill guides | Resin may not survive autoclave heat |
| Material jetting | Multi-material soft tissue models | Higher cost per part |
| FDM | Handling models, fit checks | Visible layer lines, weak in thin walls |
| 5-axis CNC | Metal guides, implant supports | Needs a machinable stock size |
| Vacuum casting | Small runs of silicone models | Soft tooling wears after a few dozen parts |
Tolerances That Matter, and Ones That Do Not
A printed anatomical model does not need ±0.005 mm. It needs the right shape at a believable scale. Chasing tight numbers on a display model wastes money and adds nothing to the surgery. The parts that do need tight numbers are the guides and the metal supports, where a hole position error of 0.5 mm can put a drill in the wrong place.
On our 5-axis centers we hold ±0.005 mm on machined features and check every part before shipment. Surface finish follows the function: Ra 0.8–1.6 μm for a guide that slides against tissue or another part, Ra 1.6–3.2 μm for a bracket that only needs to fit. A finer finish than that is rarely worth the cycle time.
Feature size sets a second limit. Printed channels below about 1 mm tend to close up or trap resin. Sharp internal corners in a machined guide need a tool radius, so design them with a fillet or move the corner out of the load path. These are the details that decide whether a design survives its first build.
If you are unsure which features are critical, send the model and we will mark the ones that drive cost. That review is free and comes back with the quote.
- 1Model shapeScale accuracy beats surface finish
- 2GuidesHole position and flatness drive function
- 3FinishRa 0.8–1.6 μm for sliding contact
- 4CornersAdd a fillet or move load away
Materials for Planning Models and Implant Supports
Planning models are usually resin or plastic. They are cheap, fast and easy to reprint when the plan changes. Medical-grade resins exist, but for a model that never touches the patient, standard resin is enough. Clean the part, cure it fully and store it away from sunlight.
Machined implant supports and fixation plates are a different category. Titanium Ti-6Al-4V (TC4) is the common choice for its strength-to-weight ratio and biocompatibility record. 316L stainless is used where corrosion resistance matters more than weight. Both machine well, though titanium needs sharper tools, lower cutting speeds and more coolant.
For instrument bodies and trial fittings, 6061-T6 aluminium is a good balance of cost and stiffness. PEEK is an option when a part must be radiolucent or tolerate repeated steam cycles. It machines like a hard plastic, so feeds and speeds differ a lot from metal, and we plan the toolpath accordingly.
Whichever material you pick, keep the lot traceable. A support part that goes into an operating room needs a paper trail from stock to finished feature, and that means material certificates stay with the job file.
- 1Ti-6Al-4VSupports and plates, high strength
- 2316LCorrosion resistance, good machinability
- 36061-T6Instrument bodies and trial fittings
- 4PEEKRadiolucent and steam-cycle tolerant
Inspection, Documentation and Confidentiality
Every part we ship is inspected 100 percent. For a surgical guide that means checking hole position, flatness and the fit surface against the drawing, not just a spot check. Reports are available on request, and we keep raw material certificates with the job.
Patient scan data is sensitive. Uploads go through a secure channel, and we sign an NDA when a customer asks. Files are used only for the quoted job and are not shared with other customers or reused in marketing material. That is a standing rule, not a per-project negotiation.
Our quality system is certified to ISO 9001:2015, ISO 13485:2016 for medical devices, IATF 16949:2016 for automotive and ISO 27001:2022 for information security. The medical certificate is the one that matters most for planning models and surgical guides, because it covers design, production and servicing of medical devices.
We are a machining and printing shop, not a regulatory consultant. We build to your drawing and your specification. Approval routes, clinical validation and sterilization decisions stay with your team and your notified body.
- 1Inspection100 percent before shipment, reports on request
- 2ConfidentialitySecure uploads, NDA on request
- 3CertificationsISO 9001, ISO 13485, IATF 16949, ISO 27001
- 4ScopeWe build to your drawing, you own approvals
Common Questions
Can 3D printing replace the machined implant support in a case like this?
No, and it is a common misunderstanding. Printed models are for planning, and printed guides can be used in the operating room, but a load-bearing support under the skin is normally machined or molded from a validated material.
The choice depends on the load, the sterilization route and the regulatory path. If a printed polymer part can carry the load and pass the approvals, it can be used. For most facial supports, metal is still the safer default.
What file formats do you accept for scan data and models?
Send the segmented surface as STL, STEP or a native CAD file, plus the original DICOM volume if you have it. The DICOM lets us re-check the scale and landmarks when a question comes up later.
For machined parts we prefer STEP or IGES over STL, because a mesh loses the exact geometry that the toolpath needs. If STL is all you have, we can work from it but will confirm critical dimensions before cutting.
How do you handle patient data privacy?
Uploads are secure and confidential. We will sign an NDA on request, and we keep scan files in a controlled folder tied to the job number rather than a shared drive.
Files are used only for the quoted work. They are not reused for other customers and are not shown in our marketing without written permission.
What lead time should we plan for a printed model and a machined guide?
Quotation and a free DFM analysis come back within 12 hours, and production can start within 24 hours of approval. Parts ship in 3–5 days for most jobs.
Those numbers assume the model is print-ready and the drawing is complete. A scan that needs re-segmentation or a design that needs a change adds time, and we will tell you that before the job starts rather than after.
Can you machine a titanium support with features for a printed guide to sit on?
Yes. We run 16 simultaneous 5-axis centers, hold ±0.005 mm on machined features, and machine titanium TC4 regularly. The guide and the support are best designed together so the mating surfaces and pin holes line up.
Send both models in one request and we will check the interface. Finding a mismatch at that stage costs a drawing revision. Finding it in the operating room costs much more.
Is there a minimum order quantity for a one-off model or guide?
No minimum order quantity. We take single prototypes through 10,000+ part runs. A one-off anatomical model or a single surgical guide is a normal job for us.
For single parts, the setup cost dominates, so a model that prints in one piece is cheaper than a model split into three. We will say so in the quote if that trade-off applies.
Send Your Scan or Model for a Quote
Upload the DICOM, STL or STEP file and we will return a quotation with a free DFM analysis within 12 hours. Every part is inspected 100 percent before shipment, and your files stay confidential.
12-hour quote100% inspectionNDA availableNo minimum order
