Advances in 3D printing and biomedical engineering in skull base and head and neck reconstruction

Curr Opin Otolaryngol Head Neck Surg. 2025 Oct 1;33(5):348-354. doi: 10.1097/MOO.0000000000001071. Epub 2025 Aug 7.

Abstract

Purpose of review: Innovations in biomedical engineering have been instrumental in advancing skull base and head and neck surgical care. This review highlights the current state of the art of engineering in head and neck and skull base surgery and sheds light on future advances that will continue to revolutionize surgical care.

Recent findings: Recent impacts of biomedical engineering include 3D virtual planning, custom prosthetics, reconstruction with inert polymers or metals, and biosynthesis for reconstructive surgery. 3D virtual planning has revolutionized the surgical management of oral cavity squamous cell carcinoma, with preoperative simulation leading to decreased operative time and improved patient-centered outcomes. The field of prosthetics has also benefited greatly from the customization gained with patient tailored, 3D printed prosthetics. Other facets of biomedical engineering, such as tissue engineering, have great potential to aid in complex reconstruction with limited resources.

Summary: The intimate anatomy of the head and neck leads to unique reconstructive needs that require creative solutions. As one example, 3D surgical planning is becoming the mainstay for osteocutaneous resections and reconstructions, particularly for oral cavity cancer. With patient-centered thinking, there are numerous opportunities for the use of evolving technology to improve patient outcomes.

Keywords: 3D virtual planning; biomedical engineering in skull base reconstruction; head and neck reconstruction; tissue engineering.

Publication types

  • Review

MeSH terms

  • Biomedical Engineering*
  • Head and Neck Neoplasms* / surgery
  • Humans
  • Plastic Surgery Procedures* / methods
  • Printing, Three-Dimensional*
  • Skull Base* / surgery
  • Tissue Engineering