Gottfried Minkenberg Jan, Bender Lara, Franz Christiane, May Rebecca, Nikoubashman Omid, Wiesmann Martin, Sichtermann Thorsten
Department of Diagnostic and Interventional Neuroradiology, University Hospital RWTH Aachen, Aachen, Germany.
PLoS One. 2025 Jul 17;20(7):e0328300. doi: 10.1371/journal.pone.0328300. eCollection 2025.
Accurate physical replicas of the Circle of Willis (CoW) are valuable for planning neuroendovascular interventions, validating computational simulations, evaluating medical devices and training physicians. Existing methods often replicate only segments of the CoW or lack geometric precision, which is critical for realistic hemodynamic simulations.
We introduce a novel, cost-effective manufacturing approach to create full-scale, patient-specific CoW models using fused deposition modeling (FDM) 3D printing and lost core silicone casting. We aim to evaluate the accuracy and reproducibility of this manufacturing process.
A patient-specific 3D model of the CoW with four saccular aneurysms was generated from time-of-flight magnetic resonance angiography (TOF-MRA) data. Three identical models were printed using FDM with acrylonitrile styrene acrylate (ASA) for the vascular structure and butenediol vinyl alcohol co-polymer (BVOH) as a water-soluble support material. The printed models were encased in a clear silicone block and the ASA core was then dissolved using acetone. Computed tomography (CT) scans were used to assess geometric accuracy through cloud-to-mesh distance calculations and centerline analysis.
The median absolute surface deviation between the replicas and the initial model was approximately 309 µm for the entire CoW, with interquartile ranges (IQR) between 360 µm and 444 µm. The aneurysm surfaces exhibited lower deviations, averaging 90 µm. Centerline analysis showed median absolute deviations in vessel radius ranging from 48 µm to 114 µm across key vascular pathways. Statistical analysis confirmed minimal discrepancies between replicas and the initial model. Each replica costs approximately €100 in materials and requires five days to produce.
The manufacturing approach produces accurate, reproducible full-scale, patient-specific CoW models, including four aneurysms. This method simplifies the production process, reduces costs and maintains high geometric accuracy, making it suitable for hemodynamic studies, device evaluation, and clinical training.
Willis 环（CoW）的精确物理复制品对于规划神经血管内介入手术、验证计算模拟、评估医疗设备以及培训医生具有重要价值。现有方法通常仅复制CoW的部分节段或缺乏几何精度，而几何精度对于逼真的血流动力学模拟至关重要。
我们引入一种新颖且经济高效的制造方法，使用熔融沉积建模（FDM）3D打印和失芯硅胶铸造来创建全尺寸、患者特异性的CoW模型。我们旨在评估此制造过程的准确性和可重复性。
利用飞行时间磁共振血管造影（TOF-MRA）数据生成一个具有四个囊状动脉瘤的患者特异性CoW 3D模型。使用FDM打印三个相同的模型，血管结构采用丙烯腈苯乙烯丙烯酸酯（ASA），水溶性支撑材料采用丁二醇乙烯醇共聚物（BVOH）。将打印好的模型封装在透明硅胶块中，然后用丙酮溶解ASA芯。通过云到网格距离计算和中心线分析，使用计算机断层扫描（CT）扫描来评估几何精度。
整个CoW复制品与初始模型之间的中位绝对表面偏差约为309 µm，四分位间距（IQR）在360 µm至444 µm之间。动脉瘤表面的偏差较小，平均为90 µm。中心线分析显示，关键血管路径上血管半径的中位绝对偏差在48 µm至114 µm之间。统计分析证实复制品与初始模型之间的差异极小。每个复制品的材料成本约为100欧元，生产需要五天时间。
该制造方法可生产出准确、可重复的全尺寸、患者特异性CoW模型，包括四个动脉瘤。此方法简化了生产过程，降低了成本并保持了较高的几何精度，适用于血流动力学研究、设备评估和临床培训。
