Rib Stabilization Model

Collaborators: Stanford Neurosurgery

In one complex Neurosurgery case, the clinical team was developing a patient-specific device to stabilize the spine and ribs. Because the patient’s anatomy and reconstruction needs were highly unusual, there was no off-the-shelf solution that could be used. A full-scale physical model was needed to help design and test a custom approach.

The goal was not simply to print the anatomy, but to create a practical platform for device development. The team needed to understand the exact relationship between the spine and ribs while also being able to repeatedly assemble, disassemble, and modify the model during the design process.

Because of the model’s size and material requirements, outsourcing the prints was prohibitively expensive. Producing the models in-house offered a more practical option, but required a custom manufacturing strategy to make the project feasible.

Figure A: Anatomically accurate 3D model of the patient’s spine and ribs printed as a single assembly to provide a full-scale reference of the native anatomy.

Figure B: Modified rib models with attachment features, allowing each rib to be individually secured to the spine model during development of the custom stabilization device.

The 3DQ Lab accepted the challenge and began by segmenting the spine and ribs as separate structures. This allowed the anatomy to be prepared in two different ways. One version was printed as a single, anatomically accurate model with all ribs attached to the spine. A second version treated each rib as an individual component, with modified attachment features that allowed the ribs to be secured to the spine model and repositioned as needed during device development.

Although the project remained time-consuming and costly, producing the models in-house significantly reduced expenses compared with outsourcing. The resulting prints provided the clinical team with a full-scale platform for developing and evaluating a personalized rib stabilization device.

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