3D Printing Gives a New Face to an Injured Cyclist

In July 2021, Dave Richards’ life changed dramatically during a bike ride with two friends in the UK’s Somerset region. The group of cyclists collided with a drunk driver who was on the phone at the wheel. Dave went under the car and lost his left eye, suffered severe burns down one side of his body and face, and had his ribs crushed on the right-hand side. After multiple reconstruction operations and rehabilitation, the cyclist has begun to get his life back together. Now, the 75-year-old has received a new 3D printed face; good news for this sports enthusiast.

The orbital prosthesis was manufactured at Bristol 3D Medical Centre NHS. The facility, which specializes in 3D imaging technologies and 3D printing, is one of the first hospitals in the UK to have 3D printers on site. The center only opened its doors in April, and Dave Richards was the first patient to receive a custom 3D printed prosthesis.

Dave Richards is passionate about biking.

The patient’s face was first digitized using a surface scanner. Then, the results were used to create different models of orbital prostheses and determine the final design. The aim was to design a customized prosthesis that would fit the patient perfectly and not restrict his movements. Finally, the PEEK prosthesis was printed on a 3D printer from the manufacturer miniFactory. This printer features a heated chamber that can reach up to 250°C, and can guarantee the quality required for medical purposes.