RE: Happy ending and copyright

From: Geoff Smith-Moritz (
Date: Mon Aug 26 2002 - 20:18:50 EEST

Thanks to Jim for publishing this story to the rpml. I’d like to add,
however, the copyright notice that was originally part of this story when it
was posted last week to the Rapid Prototyping Report’s CADCAMNet Web site.
Copyright © 2002 CAD/CAM Publishing, Inc. All rights reserved.
The following article is protected by the copyright laws of the United
States and 100 other countries. It is licensed to you for personal and
business use subject to the following restrictions:
    -No copies of this information may be posted on any other Web site.
    -No copies may be sent by e-mail to any other persons.
    -Articles may be printed for personal use only.
Violators may be subject to civil action and criminal penalties. CAD/CAM
Publishing, Inc., 1010 Turquoise Street, Suite 320, San Diego, California
92109 Telephone: (858) 488-0533 FAX: (858) 488-6052 e-mail: <> .

Geoff Smith-Moritz
Rapid Prototyping Report
San Diego, California

Telephone: (858) 488-0533

Current and past CAD/CAM Publishing articles can
be read from the Web site:
<> /

-----Original Message-----
From: []On Behalf Of
Jim Leonard
Sent: Saturday, August 24, 2002 6:16 AM
To: rp-ml
Subject: Happy ending

Here is another story which shows rapid prototyping at its best. Nice job
Interpro and Objet.

Rapid prototyping helps separate conjoined twins
August 15, 2002 -- Maria Teresa and Maria de Jesus Quiej-Alvarez were born
on July 24, 2001 in a rural village in Guatemala. Together, they weighed 4.4
pounds at birth and, despite their small size, were healthy in every way --
except for being joined at the head. Over the past year, the girls have
remained healthy and happy but they have been severely restricted by their
condition. Recently, a nonprofit organization called Healing the Children
( <> )
arranged for the girls to be flown to Los Angeles where a volunteer team of
neurosurgeons and plastic surgeons at the University of California Los
Angeles (UCLA) Mattel Childrens’ Hospital successfully separated them in a
22-hour-long operation. Today, both girls are doing well, and the prognosis
for both is excellent. Without rapid prototyping, say the doctors, the
operation would have been much more difficult.

Conjoined twins Maria Teresa and Maria de Jesus Quiej-Alvarez.
Biomodels -- medical rapid prototypes
For some years, rapid prototyping has found limited acceptance in the
medical world, but most doctors, skilled at reading x-rays, magnetic imaging
data, and computed tomography scans, don’t know about the technology. Those
who do often feel that rapid prototyping delivers no more information than
other methods.
However, a small number of surgeons, particularly those doing complex facial
reconstructions, have found that building rapid prototyping models of
underlying bones and using them to plan procedures can shave hours off the
time required for actual operations. In some cases, use of biomodels can
eliminate the need for exploratory operations altogether.
Maria y Maria
For a physician, separating conjoined twins is one of the most complicated
procedures imaginable. Intertwining bones, nerves, blood vessels, and other
tissues force doctors planning such operations to abandon everything they
know of normal anatomy and chart from scratch the way each of these unique
pairs is arranged. In the case of the two Marias, x-rays showed that the
girls did, in fact, have separate and complete brains, normal in size and
structure and separated by a membrane. This meant that the surgeons would
not have to cut through any brain tissue. The arteries that carried
oxygenated blood to their brains were also separate, but the veins that
drained the blood were interwoven and fed into each other’s circulatory
systems. The most complex part of the operation would be to sort out these
veins and reroute each girl’s blood supply. And this is where rapid
prototyping played an essential role.

X-rays showed the girls had separate, fully developed brains but also had
crisscrossed blood vessels. Tracking those blood vessels on the
two-dimensional X-rays, however, was next to impossible.
The surgical team was headed by Dr. Henry Kawamoto, director of craniofacial
surgery at UCLA, and Dr. Jorge Lazareff, director of pediatric neurosurgery
at the Mattel Children’s Hospital. A doctor on the team had used rapid
prototypes previously and convinced the lead surgeons that such models might
be useful in this case, enabling the plastic surgeons to practice how to
separate the two girls’ skulls and plan how they might graft skin to cover
their brains once separated. For the neurosurgeons, physical models would
help sort out the maze of interconnected blood vessels.
So the team contacted Biomedical Modeling Inc. (BMI) ( <> ) in Boston. According to
company founder Eitan Priluck, Biomedical Modeling is one of a handful of
companies worldwide whose sole business is fabricating rapid prototypes for
medical use. When the UCLA medical team first contacted BMI, Priluck says,
there was only about a week left before the scheduled surgery. The UCLA
physicians supplied BMI with a series of computed tomography (CT) scans of
the two girls. Complicating the task was the fact that the two girls, while
connected, couldn’t be arranged in the CT system so that a single scan of
their heads could be made. Instead, three sets of scan data were collected
at different angles and BMI had to register and combine them into a single
three-dimensional model.
Priluck says his team used Materialise’s MIMICS software to combine the
scans and process the data. In most cases, he says, doctors want biomodels
built of either bone or soft tissue but not the two combined. With MIMICS,
he says it’s relatively simple to set thresholds to capture such
distinctions. In this case, however, the surgical team wanted a biomodel of
the skull that included the blood vessels, which made the job more
challenging. He says it took about three days to process the CT data and
create STL files for rapid prototyping.
In the past, says Priluck, BMI has used various rapid prototyping
technologies, most often stereolithography, because it delivers crisp models
with good definition. But this case presented some challenges that made the
use of stereolithography problematic if not impossible. With a
stereolithography model, the maze of blood vessels would have required
support structures that would have been next to impossible to remove. So
Priluck decided to see if a new rapid prototyping technology might be more
Priluck contacted InterPro (
<> ), a nearby rapid prototyping service
provider in Deep River, Connecticut. InterPro operates stereolithography and
selective laser sintering systems as well as a 3D Systems ThermoJet concept
modeler. In addition, it recently took delivery of an Objet Tempo rapid
prototyping system. The Tempo, made by the Israeli company Objet Geometries
Ltd. ( <> ), builds parts by
selectively jetting tiny droplets of acrylate photopolymer and then curing
the drops, layer by layer, with light. Unlike stereolithography, which uses
the primary building material for supports that must be cut or sanded away,
the Tempo employs a second photopolymer for supports that never fully
harden. Once a part is complete, this gel-like support material can be wiped
off or removed by water jet.
InterPro co-owner Kevin Dyer agreed that the task seemed well-suited to the
abilities of the Tempo and offered to build three parts, one of each girl’s
skull and one of the junction between the two. Dyer says the STL files
supplied by BMI were large, about 80 megabytes each, but contained no flaws.
He says his team verified the data, determined the optimum orientation of
each part in the Tempo’s build chamber, and started building. He says it
took about 24 hours to build each of the three parts.

Biomedical Modeling Inc. and InterPro made models of each girl’s skull.
Once they were built, Dyer says removing the Objet support material proved a
bit more challenging than he had anticipated. Because the blood vessels were
so delicate, it was impossible to blast away the support gel with a water
jet without also damaging the fragile structure. So Dyer says his team had
to spoon out and clean off the support material by hand, at times heating
the parts with warm water to further soften the material. He says his
technicians had to check the data constantly to make sure they didn’t remove
critical parts of the models. In all, he says, it took about eight hours to
clean the parts.

They also made a model of the region where the two skulls connected so that
the surgeons could study the maze of blood vessels.
Priluck says he shipped the parts to UCLA as soon as he received them from
InterPro, and the doctors were delighted with them. Kawamoto’s
plastic-surgery team used strips of felt representing the girls’ skin to
plan how they would cover the skulls once the twins were separated. And
Lazareff’s group used the model of the intersection of the two skulls to
help plan how it would reroute the necessary blood vessels. The operation
took about 22 hours to complete. Similar procedures in the past, says
Priluck, have taken as long as 97 hours. Part of this time savings almost
certainly was attributable to the rapid prototyping models. Says Kawamoto,
“No matter how good our 3D graphics are, there is nothing like holding a
model in your hands.” Contact: Biomedical Modeling, Inc., 1085 Commonwealth
Avenue, P.O. Box 312, Boston, Massachusetts 02215 Telephone: 1 (617)
738-8168 or InterPro, 630 Industrial Park Road, Deep River, Connecticut
06417 Telephone: 1 (860) 526-5869.

Plastic surgeons rehearsed with the models to help plan how they would
arrange skin to cover the openings created by the operation.

Lead surgeon Henry Kawamoto, “No matter how good our three-D graphics are,
there is nothing like a model in your hands.”

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