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March 21, 2026MaterialsOpen Access

Advanced Manufacturing of PLA Surgical Templates for Orbital Floor Geometry: Optimizing Fidelity and Surface Morphology via Variable Layer Height MEX 3D Printing

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Authors

PTP TurekRzeszów University of TechnologyGBGrzegorz BudzikRzeszów University of TechnologyŁPŁukasz PrzeszłowskiRzeszów University of Technology

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Overview

Demonstrates improved surgical templates in maxillofacial surgery, indicating enhanced efficiency and precision.

Key Points

  • The research aims to enhance the production of personalized polylactide surgical templates for orbital floor reconstruction.
  • Developed the TARMM procedure to optimize PLA template production.
  • Utilized machine learning algorithms, specifically Random Forest, to reduce reconstruction artifacts.
  • Implemented Material Extrusion (MEX) technology with Variable Layer Height (VLH) for better surface morphology.
  • Conducted clinical validation across 21 cases to assess performance and efficiency.
  • Achieved a geometric error within ±0.1 mm for the templates.
  • Found a strong linear correlation (r = 0.99) between layer height and surface roughness (Sa).
  • Demonstrated that a 0.07 mm layer significantly improves template morphology.
  • Confirmed a reduction of 30 minutes in surgical preparation time.

Cite This Study

Turek et al. (2026) studied this question.

synapsesocial.com/papers/69be37ce6e48c4981c677b8bhttps://doi.org/10.3390/ma19061208
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Also Consider

Synapse has enriched 5 closely related papers on similar clinical questions. Consider them for comparative context:

  1. 13D Printing and Virtual Surgical Planning in Craniofacial and Thoracic Surgery: Applications to Personalised Medicine2025
  2. 2Clinical Feasibility and Surgical Outcomes of a 3D-Printed Template-Based PMMA Implant Workflow for Genioplasty2026
  3. 3Large-scale manufacturing of precisely patterned flexible soft tissue implants with high porosity2026
  4. 4Virtual and Rapid Prototyping of Personalised Medical Devices in Maxillofacial Surgery: An Engineering Design Approach and Collaborative Platform2026
  5. 5Mesh Optimisation for General 3D Printed Objects with Cusp-Height Triangulation Approach2024