With over a decade of experience in additive manufacturing, Kevin drives the success of Stratasys Direct’s 3D printing services portfolio, shaping material strategies, optimizing product sales, and enhancing customer experience through e-commerce platforms. He has expertise in powder bed fusion technologies like SLS, SAF, and MJF, contributing to material development and process innovations in industries such as aerospace, automotive, and consumer goods. Kevin holds both a BS and an MSE in Mechanical Engineering from the University of Texas at Austin and is an active speaker at industry conferences like AMUG and RAPID + TCT.
Surgical success depends on preparation, understanding a patient’s unique anatomy, planning the right approach, and minimizing time under anesthesia. Increasingly, hospitals are turning to 3D printed medical models to meet these needs. Real-world case studies from Queen Elizabeth Hospital and Biodonostia Health Research Institute show how these tools are changing surgery from reactive to proactive.
At Queen Elizabeth Hospital in Birmingham, UK, the maxillofacial team faced a recurring challenge: complex tumor resections that required bone grafts or titanium plates to reconstruct facial anatomy. Traditionally, the custom-fitting of these components was done during surgery, often extending time on the table by hours.
Utilizing Polyjet technology, the hospital began producing patient-specific anatomical models and cutting guides directly from CT scans. This enabled surgeons to rehearse procedures and pre-fit implants before the first incision.
The impact was immediate: 3-4 hours of OR time saved per surgery, surgical planning time reduced by 93%, and cost savings up to £20,000 per case!
These gains weren’t limited to a single department though. 3D printing has since been adopted across ENT, burns, plastic surgery, and neurosurgery units
A similar story unfolded at Biodonostia Health Research Institute in Spain. Faced with a patient whose thoracic wall tumor spanned multiple ribs, the surgical team used FDM technology to 3D print an exact replica of the tumor site using engineering-grade thermoplastics. This allowed them to perform the resection beforehand on the model, measure and pre-bend titanium plates, and reduce OR time by 2 hours.
For the hospital, that meant not just a smoother operation, but fewer complications from extended anesthesia, less blood loss, and quicker OR turnover.
The accuracy of these printed models plays a critical role in complex cases. At Queen Elizabeth, the team used models to custom-design bone grafts, ensuring they fit seamlessly and reducing the margin for intraoperative error. In surgeries involving critical facial nerves or asymmetrical bone structures, sub-millimeter-level accuracy can be the difference between successful reconstruction and long-term complications.
At Biodonostia, the strength of the 3D model was also key. Surgeons needed a model that mimicked the density and resistance of human bone to practice the unusual approach of removing multiple ribs. The FDM-printed model enabled them to test surgical paths and implant fits without relying on estimation.
“Without the strength of this model, we could not have prepared for the surgery in the same way,” said Dr. Jon Zabaleta, thoracic surgeon at the institute.
“Without the strength of this model, we could not have prepared for the surgery in the same way,” said Dr. Jon Zabaleta, thoracic surgeon at the institute.
Beyond technical planning, the presence of a tangible 3D model transforms how surgeons communicate with patients. At both hospitals, clinicians reported that patients better understood their diagnosis and the proposed surgery when shown a model instead of a CT scan or 2D image.
At Queen Elizabeth, patients could see exactly what part of their face would be reconstructed, using a visual reference that mirrored their anatomy.
At Biodonostia, the 3D printed model helped reduce patient anxiety before surgery and made the consent process faster and more meaningful.
“It helped us explain how we would protect the lungs,” said Dr. Zabaleta. “That clarity improved the patient’s confidence and engagement, which is critical in high-risk surgeries”.
The use of 3D printed medical models is no longer experimental; it’s essential. From dramatically shortening surgeries and deepening patient trust, these tools enable a more precise, personalized, and proactive approach to care. As adoption grows, it’s clear that the surgical standards of tomorrow are being shaped by 3D printing today.
