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CAD/CAM silicone auricular prosthesis with thermoformed stiffening insert

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

Archives of Materials Science and Engineering

2017

Vol. 83, nr 1

30--35

Purpose: Epitheses (facial prostheses) for large facial tissue defects manufactured from silicones exhibit unsatisfactory rigidity and its stiffening is required, which creates technological problems. Moreover, facial epitheses have to be replaced in a relatively short period of use which creates a significant costs, often impossible to realize. The hypothesis of the study was that with use of additive manufacturing is possible to obtain the reusable form for thermoforming of the stiffening insert of auricular prosthesis and the mould which allows multiple casting of silicone prosthesis with the insert. Design/methodology/approach: Manufacturing of the epithesis consisted of designing and manufacturing. In the first step, the auricular prosthesis and the stiffening insert were designed with use of engineering CAD software. In this first computer step, the split form for vacuum thermoforming of the stiffening insert and the split mould for casting of the silicone ear were designed. In the second step, additive printing was used for manufacturing the split and reusable model for vacuum thermoforming of the stiffening insert and the split form of ear. In the third step, stiffening insert was made of thermoformed polyurethane sheet of 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 was casting of silicone. Findings: CAD/CAM of epitheses with stiffening insert for large tissues defect/loss was proposed, where in case of re-producing, it required only thermoforming of insert and casting silicone with use of the reusable models. Dental technician, in case of damage or loss of a forms, is not much involved in their creation. Research limitations/implications: Bond strength test between stiffening insert vs. soft silicone and manufacturing tolerance of epitheses have not been investigated. Practical implications: Method of casting in a negative form, despite the more timeconsuming when comparing with epithesis direct-printing, allows introducing a stiffening insert and performing a manual adjustment of margin shape and thickness. Method of negative form allows the use of a commercially available medical silicone without the need for medical tests of a new printed materials.