Planning Impossible Surgeries with Personalized 3D Printed Tumor Models

Posted on 5 February 2020 by Jessica James

3D LifePrints are building an excellent reputation for creating physical phantoms as a solution for surgical planning. The company use Synopsys’ Simpleware software as part of their model generation process, providing innovative options for difficult clinical situations through medical 3D printing. In 2019, 3D LifePrints worked with Alder Hey Children’s Hospital in Liverpool, UK to aid in the surgery for a 6-year-old girl with a large, ‘impossible’ tumor, with their models proving key to the pre-surgical planning process.

The “Impossible” Tumor

After several months of severe back pain, Leah Bennett was admitted to the Alder Hey Hospital for tests, whereupon a large tumor was detected at the base of her spine. The clinicians working on Leah’s case found that the cancerous mass was close to a number of important anatomical regions, including the spinal cord and superior mesenteric artery, and enveloped large parts of crucial vessels such as the aorta and the inferior vena cava.

Chemotherapy was attempted and proved ineffective, resulting in the need for surgical intervention. However, clinicians from around the country were cautious about attempting surgery, due to the risk of life-threatening blood loss during an operation. Alder Hey’s surgeons then turned to their in-house Innovation Hub, headed by surgeon and Clinical Director of Innovation Ian Hennessey, as well as 3D LifePrints, who have been embedded at the hospital for almost five years. Surgeon Jo Minford worked with this team to create a 3D printed model of the tumor and surrounding anatomical areas, with the goal of improving pre-surgical planning and lowering the risk of complications.

Creating a 3D Printed Anatomical Model

3D LifePrints used Simpleware software as part of an urgent workflow to model the patient’s anatomy and the tumor. Leah’s CT scan data was imported to Simpleware software for segmentation, before a file was exported to be printed using a Stratasys 3D printer. The workflow for processing the CT scan data and getting to a 3D printed model was aided here by the software’s ease-of-use, and ability to generate files ready for 3D printing.

Surgical Outcomes

Using the 3D LifePrints model, the surgical team were able to review and agree on the best possible approach to what became an eight-hour operation, with three surgeons from Alder Hey and one from Royal Liverpool University Hospital involved. The surgeons were able to remove 90% of the tumor with no complications. Leah has since completed radiotherapy at Clatterbridge Hospital, and is making a recovery. This case shows how seemingly ‘impossible’ surgeries are being made more practical by linking 3D images to printed models, with other applications including the use of models as part of targeting references for patient radiotherapy.

Learn More About Leah’s Story

• Video posted by Alder Hey Children's Hospital: Leah Bennett - The Impossible Tumour
• TV Interview with Leah and her father on the BBC Breakfast show: Leah has had successful 3D surgery for her "impossible" tumour