Comparison between Custom 3D-Printed Titanium Meshes and Stock Titanium Meshes in Orbital Floor Repair: A Retrospective Analysis.

PURPOSE: To compare the clinical outcomes of patient-specific customized 3D-printed titanium meshes (PSIs) and stock titanium meshes in orbital floor reconstruction.

METHODS

This retrospective case series included 48 patients undergoing orbital floor repair between June 2024 and March 2025. Patients were divided into Group 1 ( n = 22) receiving custom 3D-printed titanium meshes and Group 2 ( n = 26) receiving stock titanium meshes. Operative time, orbital volume restoration (via 3D volumetric analysis), resolution of enophthalmos, diplopia, and infraorbital paresthesia were assessed. Volumetric measurements were performed using semi-automatic segmentation based on CT scans.

RESULTS

The 3D-printed meshes achieved a better restoration of orbital volume, with a mean reduction in volumetric discrepancy of 89% (SD ± 28%), compared to 51% (SD ± 35%) in the standard mesh group ( P = 0.036). No statistically significant differences were observed in operative time or in the resolution of paresthesia. However, a statistically significant difference between the two groups was found in the resolution of both enophthalmos and diplopia ( P = 0.025 and P = 0.028).

CONCLUSION

Custom 3D-printed titanium meshes showed improved anatomical accuracy and volumetric outcomes compared to stock meshes. Further prospective studies with long-term follow-up are necessary to confirm these findings and assess cost-effectiveness.