A novel 3D-printed noninvasive immobilizer for head stability during surgery of the orbit and skull base.

BACKGROUND: This study investigates a 3D printed, noninvasive headrest that was designed for use in orbital and skull base surgeries and compares the stability of this innovative headrest to conventional head immobilization devices using accelerometer-based measurements. METHODS: A 3D model of a headrest was developed using two plastic materials: polyethylene terephthalate glycol (PETG) and thermoplastic polyurethane (TPU). Stability, in g-force, was measured for these headrests, Gel Head Donut Adult Blue Diamond®, and a no headrest condition. A non-embalmed cadaver’s head was placed in each headrest condition and subjected to controlled oscillations using Bellco Glass’ Orbital Shaker. Acceleration data were recorded over a 3-second interval. RESULTS: The average acceleration, measured in g-force (g), over 3 s for each headrest configuration was: (1) no headrest: 0.068116 g ± 0.058498, (2) Gel Donut head immobilizer: 0.064223 g ± 0.027463, (3) PETG headrest: 0.053331 g ± 0.037782, and (4) TPU headrest: 0.056254 g ± 0.032200. The PETG headrest showed a 21.71% improvement over no headrest and a 16.96% improvement over the gel donut headrest in maintaining head stability. And the TPU headrest showed a 17.41% improvement over no headrest and a 12.41% improvement over the gel donut headrest in maintaining head stability. CONCLUSIONS: The PETG and TPU headrest provided greater stability compared to the commonly used Gel Head Donut headrest and in the absence of a headrest. This study suggests that the design of this headrest offers a potential noninvasive head stability device, regardless of material composition, that may improve the safety and efficacy of orbital and skull base surgery.