3D Printing and Facial Prosthetics are Changing the Game for Cancer Patients

After suffering a variety of cancers and surviving their treatments of surgery, chemotherapy and/or radiation, patients are often left with what may seem like irreparable damages. Some cancers can be hidden, but others are on full display for all to see and they take a toll on the body and the psyche. They rob patients of their physical appearance, their confidence and dignity. The good news is that treatments to help these patients have improved drastically.

Today, 3D printing technology is a game changer for facial prosthetics. It allows the prosthesis to be fabricated quicker and more accurately. Most importantly, it's changing the way patients see themselves after rounds of fighting aggressive head and neck cancers.

"3D printing technology is standard in our pre-surgical planning and has become part of our treatment plans with head and neck reconstruction surgeries,” said Betsy Davis, DMD, MS, oncologic dentist at Trident Medical Center's Head and Neck Specialists.

Jackie Hyman was diagnosed with Wegener's disease, a rare autoimmune disease that restricts blood flow to internal organs like the lungs, kidneys, throat, and tissues like the ears and nose. She had a severe case and it caused significant damage to her nose and surrounding tissue.

Hyman battled the disease and its progression since 2006 and underwent over 50 unsuccessful surgeries and procedures to rebuild her nose lost to the disease. Her hopes of looking like her old self again were dashed until she met Dr. Davis, then her outlook and her prognosis changed.

Maxillofacial prosthetics is a unique subspecialty for Davis. “I'm honored that in my line of work I can help a patient return to their previous quality of life and not be self-conscious about their appearance post cancer treatment. It gives them dignity that they need and deserve,” she adds.

Facial Prosthetics - Building Confidence

Based on a 3D CT scan we can tailor make a facial prototype designed specifically for a patient's individual needs. “For example, we can construct a nasal, orbital, or ear prosthesis that mimics their exact skin tone and texture for a more natural look and feel,” Davis notes.

In fabricating a facial prosthesis, we use data from a CT scan or digital scanner to create a mockup or prototype of the facial prosthesis.

• For an ear prosthesis, we can use the contralateral ear and flip it to the affected side so that both ears are symmetrical.
• For a nasal prosthesis, we can use the data from the preop CT scan to use as a guide for the shape of the nasal prosthesis.

The prototype is then adapted to the patient's affected area, scanned digitally and printed. Then the patient has a fitting and the final adjustments are made.

The skin color can be measured using a device called a spectramatch to ensure the prosthetic will be a match to the patient's skin color and tone. The final step is to have the model converted into silicone and then it is hand painted and “tweaked” with the patient present to get the color just right.

What are Patients Saying?

Davis, has been making prosthetics since 1994 and is one of the few prosthetics makers in the South. She made Hyman's first prosthetic nose in 2017.

“She saved my life and she saved my face,” Hyman exclaims.

“I think head and neck cancer is the most devastating cancer because it can't be hidden,” Davis says. “We live in a world where we are often judged by our appearance. To be able to restore facial appearance and help the patient return to society is very rewarding.”

The 3D printing is such a life changer for so many patients who lose a portion of their face from cancer - an eye, nose or ear. Davis adds, “It is truly a gift to be able to rehabilitate the patient through a prosthesis that is personalized for each patient. It allows for them to resume their work and play as before and get back to family events, outings, travel with less concern and worry about ongoing treatment.”