Technical report: A Seamless Digital Technique for Manufacturing Soft-Tissue Facial Prostheses Using 3D Color Printing Technology

Abstract

This technical report presents a novel digital workflow for fabricating soft-tissue facial prostheses using full-color 3D printing technology. Developed from Faraedon Zardawi’s doctoral research, the method integrates 3D photogrammetry, CAD modeling with skin-tone mapping, binder-jet 3D printing (ZCorp Z510), and silicone elastomer infiltration (Sil‑25) to create lifelike, implant-retained facial prostheses. The workflow achieves significant improvements over traditional hand-crafted silicone prostheses in terms of color fidelity, reproducibility, fabrication speed, and patient comfort. A dedicated color management system ensures accurate and repeatable reproduction of skin tones. Mechanical and durability testing revealed that while the 3D printed prostheses exhibit reduced tensile strength and flexibility compared to conventional silicone, their color accuracy and aesthetic quality remain clinically viable for interim use. Infiltration depth and UV stability were also studied, highlighting areas for future material optimization. This approach is particularly suitable for patients undergoing healing post-surgery, offering a customizable, cost-effective, and easily reproducible interim solution with a functional life of 4–6 months. The digital archive of patient data allows for efficient updates to the prosthesis in response to tissue changes. Although limitations in mechanical performance and environmental stability persist, these are offset by clinical benefits and the potential to print multiple units for each patient. This work underscores the feasibility and future promise of 3D color printing in maxillofacial rehabilitation, bridging design innovation with patient-specific care.