A CAD-Based Tool for Tissue-Mimicking Replica of Human Costal Cartilage

Ear reconstruction surgery is a very demanding intervention for plastic surgeons. The results rely heavily on the “artistic skills” of the surgeon who has the task of creating a three-dimensional sculpture using harvested costal cartilage capable of replicating the shape of a physiological ear. By exploiting a combination of Reverse Engineering, CAD modelling, and Additive Manufacturing tools, it is possible to create efficient and highly personalized simulators to train and support the surgeon before and during surgery. In fact, the flexibility of these techniques allows the development of custom-made medical devices, designed directly on the patient's anatomy. In order to make the simulation as realistic as possible, this work focuses specifically on the creation of accurate costal cartilage replicas, both in terms of geometry and mechanical properties of the material, addressing two aspects: the systematization and automation of the CAD mould modelling procedure and the study of the most efficient mould casting materials.