CRANIOPLASTY WITH A PROSTHESIS MADE FROM A 3D-PRINTED MOLD IN A PATIENT WHO SUFFERED SEVERE TRAUMATIC BRAIN INJURY

Authors

  • Filipi Da Silva Araujo Universidade Estadual do Oeste do Paraná.
  • Laura Maria Milharezi de Souza Western Paraná State University image/svg+xml
  • Edson Kichie Mario Noguchi Western Paraná State University image/svg+xml
  • Manuela Yphyn Faria Sung Western Paraná State University image/svg+xml
  • Maria Helena Adriano Western Paraná State University image/svg+xml
  • Gabriela Cavalieri de Oliveira Western Paraná State University image/svg+xml
  • Paulo Ricardo Correa Schmidt Western Paraná State University image/svg+xml
  • Marcius Benigno Marques dos Santos Western Paraná State University image/svg+xml

DOI:

https://doi.org/10.48075/vscs.v11i1.36386

Abstract

Cranioplasty is a surgical procedure that reconstructs the skull in cases of defects resulting from various causes, with a direct impact on brain protection and the patient's social reintegration. At the University Hospital of Western Paraná (HUOP), cranioplasty with polymethylmethacrylate (PMMA) is routine, but intraoperative manual molding can lead to unsatisfactory aesthetic results. However, there are financial limitations within the Brazilian Unified Health System (SUS) for the use of more sophisticated techniques, as the cost of industrial molds and ceramic or titanium prostheses can exceed R$ 100,000. Thus, there is a need to validate low-cost methodologies, ensuring anatomical precision. This work presents an experience report on the fabrication of a customized mold using a non-industrial 3D printer and the production of a prosthesis with PMMA. An 11-year-old male patient suffered severe traumatic brain injury in November 2021, requiring left decompressive hemicraniectomy, which resulted in a persistent bone defect in the cranial vault. After clinical stabilization and correction of complications, cranioplasty was indicated for brain protection and aesthetic correction. We used the patient's computed tomography images to create a virtual mold, which was 3D printed with biocompatible material, sterilized, and then used as a mold to create the PMMA prosthesis during surgery. The prosthesis was implanted and fixed to the skull according to the standard technique. We conclude that the described technique proved viable, allowing for a cost reduction to less than R$ 800.00, with satisfactory aesthetic results.

Author Biographies

  • Filipi Da Silva Araujo, Universidade Estadual do Oeste do Paraná.

    The project author is a medical student with a strong interdisciplinary background. Responsible for advanced image processing, he developed high-fidelity three-dimensional models for personalized surgical planning. He played a key role in the conception and optimization of custom-made prosthesis manufacturing techniques, integrating knowledge of anatomy, engineering, and digital technologies. During surgical procedures, he excelled in providing intraoperative support, ensuring the precise application of prototyped solutions. Furthermore, he rigorously conducted the collection, organization, and analysis of clinical data, ensuring the scientific robustness of the study. His dedication reflects a commitment to technical excellence and the transformative impact of personalized medicine.

  • Laura Maria Milharezi de Souza, Western Paraná State University

    A medical student committed to scientific excellence and clear communication, she excelled in the visual conception and narrative structuring of the project. Responsible for curating and preparing illustrative images, designing diagrams that accurately translate the central concepts of the research, constructing the institutional presentation integrating technical rigor and visual aesthetics, and meticulously reviewing the text, ensuring cohesion, terminological precision, and argumentative fluency. Her contribution was fundamental in ensuring that the proposal was not only scientifically sound but also accessible, impactful, and aligned with academic standards.

  • Edson Kichie Mario Noguchi , Western Paraná State University

    Medical student dedicated to scientific and clinical research, involved in the methodological direction of the project. Responsible for the critical analysis and systematic review of medical records, rigorous research and synthesis of scientific literature, and textual refinement of study documents, ensuring clarity, precision, and adherence to academic standards. Their contribution integrates technical rigor, critical thinking, and a commitment to the quality of scientific output.

  • Manuela Yphyn Faria Sung, Western Paraná State University

    A medical student dedicated to clinical research and scientific production, she plays a fundamental role in leading the project by conducting clinical patient assessments, detailed analysis of medical records, and rigorous literature reviews. Furthermore, she contributes with sensitivity and precision to textual editing, ensuring clarity, coherence, and academic rigor in all materials produced. Her work integrates technical knowledge, ethical commitment, and attention to detail, reflecting her deep dedication to the quality of care and research in healthcare.

  • Maria Helena Adriano, Western Paraná State University

    Medical student actively participating in the project, responsible for clinical patient assessments, meticulous analysis of medical records, and continuous research for updated and reliable scientific literature. Responsible for reviewing and improving the textual aspects of study documents, ensuring conceptual accuracy and fluency in scientific communication. Guided by ethical principles and a genuine commitment to improving healthcare.

  • Gabriela Cavalieri de Oliveira, Western Paraná State University

    A resident physician in Neurosurgery, with a solid clinical and surgical background, plays a central role in the project by conducting comprehensive clinical evaluations of patients, ensuring rigorous diagnosis and careful case selection. She was the main creator and developer of the sterilization protocol, aligning safety practices with infection control standards in neurosurgery. Furthermore, she is directly involved in performing surgical procedures, integrating technical skill, up-to-date scientific knowledge, and an ethical commitment to patient safety and well-being.

  • Paulo Ricardo Correa Schmidt, Western Paraná State University

    A neurosurgeon with a solid clinical background and a deep commitment to innovation in healthcare, he conceived the central methodology of this project and designed the first prototypes. His technical expertise, combined with strategic vision and creative sense, allowed him to translate complex challenges of neurosurgical practice into new solutions, establishing the conceptual and operational foundations that guide all research development.

  • Marcius Benigno Marques dos Santos, Western Paraná State University

    A neurosurgeon and professor at the State University of Western Paraná (UNIOESTE), where he holds a leading academic and scientific role. In this project, he acts as general supervisor, contributing his extensive clinical and academic experience to strategically guide the methodological design, ensure the scientific rigor of the study, and guarantee excellence in knowledge production. His supervision covers everything from the initial stages of formulating the research question to the critical review and final approval of the manuscript.

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Published

17/01/2026

Issue

Vol. 11 No. 1 (2025): Publicação Anual da Revista Varia Scientia-Ciências da Saúde

Section

Experience Report

License

Por meio deste instrumento, em meu nome — e em nome dos demais autores porventura existentes —, cedo os direitos autorais do referido artigo à Universidade Estadual do Oeste do Paraná e declaro estar ciente de que a não-observância deste compromisso submeterá o infrator a sanções e penas previstas na Lei de Proteção de Direitos Autorais (n.9609 de 19/02/98).

How to Cite

CRANIOPLASTY WITH A PROSTHESIS MADE FROM A 3D-PRINTED MOLD IN A PATIENT WHO SUFFERED SEVERE TRAUMATIC BRAIN INJURY. Varia Scientia - Ciências da Saúde, [S. l.], v. 11, n. 1, p. e36386, 2026. DOI: 10.48075/vscs.v11i1.36386. Disponível em: https://e-revista.unioeste.br/index.php/variasaude/article/view/36386. Acesso em: 5 jun. 2026.