The 3D Gens medical team has documented the full research and development workflow for a patient-specific 3D printed helmet designed for use in post-craniectomy rehabilitation. The video, shared by Hafiz Jefferi from 3D Gens' medical division, walks through every stage of the digital design process — from CT scan data acquisition to the final printed device.
This article references a video post. You can view the original on LinkedIn: Watch on LinkedIn
What Is a Post-Craniectomy Helmet?
A craniectomy is a surgical procedure in which a portion of the skull is removed — typically to relieve pressure on the brain following severe trauma, stroke, or infection. After the acute phase of treatment, patients may spend weeks or months without that section of skull while they recover. During this period, the exposed brain tissue is vulnerable.
A protective helmet serves as an external skull substitute during rehabilitation: protecting the defect site from accidental impact while the patient recovers strength and function. For the protection to be adequate and the device to be comfortable for extended wear, it must fit the patient's head geometry precisely.
The Digital Workflow
3D Gens' approach to the post-craniectomy helmet follows a fully digital workflow:
- CT Scan Data — the patient's head geometry is captured from existing CT scan data, providing a precise three-dimensional map of the skull and defect anatomy
- Digital Segmentation and Modelling — the scan data is processed to create a 3D model of the patient's head, which is then used as the basis for designing the protective helmet
- Design for AM — the helmet design is optimised for 3D printing, considering geometry, wall thickness, ventilation, and the securing mechanism
- 3D Printing — the device is produced in a polymer material selected for its combination of impact resistance, weight, and biocompatibility
- Post-Processing and Fitting — the printed helmet is finished and evaluated for fit before delivery to the patient and clinical team
This workflow illustrates how additive manufacturing enables a level of patient-specific customisation in external medical devices that was previously difficult or extremely expensive to achieve.