3D-printed cranioplasty molds – a technical note on lessons learned and things to avoid

Abstract 3D cranioplasty for cranial defects is growing ever more prevalent. As the technology becomes more accessible, the number of professionals being introduced to it is constantly on the rise. Herein we share our experience with 3D cranioplasty, point out the pitfalls and things to avoid. The commentary is structured so as to cover the entire process, from both the engineering, and medical aspects. We discuss issues relating to data acquisition, modelling, printing, material selection, post-processing, and intraoperative issues. We point out the most common problems we have encountered in our work and hope it serves as a learning base for others to avoid them.