Vol.:(0123456789) 1 3 J. Maxillofac. Oral Surg. https://doi.org/10.1007/s12663-024-02112-9 CLINICAL PAPER Mandibular Reconstruction Modalities Using Virtual Surgical Planning and 3D Printing Technology: A Tertiary Care Centre Experience Adarsh Kudva 1  · Joseph Thomas 2  · Mehul Saha 1  · G. Srikanth 1  · Abhay T. Kamath 3  · S. M. Abhijith 1   Received: 4 December 2022 / Accepted: 7 January 2024 © The Association of Oral and Maxillofacial Surgeons of India 2024 reconstruction techniques. Increased accuracy, rehabilita- tion of normal anatomical confguration, appropriate dental rehabilitation, decreased intra-operative time and post-oper- ative complications are some of the advantages. In addition, patient-specifc implants eliminate the need for a separate donor site. 3D printed titanium cribs or meshes not only provide robustness, but also incorporates additional fea- tures that enable bone graft placement and excellent dental rehabilitation. Conclusion These modalities show promising results for reconstruction of complex mandibular defects. Keywords Mandibular reconstruction · Virtual surgical planning · 3D printing technology · Patient-specifc implants Introduction Head and neck surgeons are often faced with the chal- lenge of complex mandibular reconstruction surgeries following resection. Mandibular defects can result from resection of various pathologies such as benign or malig- nant tumours, from post-traumatic bone damage, or from bisphosphonate or medication-related osteonecrosis of the jaw [1]. Reconstruction modalities have evolved with time, with each technique getting better than the previous in terms of precision, function, and aesthetics. Alloplas- tic implants, most commonly, mandibular reconstruction plates have been widely used for mandibular rehabilita- tion for a long time [2]. However, freehand adaptation of the plate can create errors and have an adverse effect on the anatomical outcome. This is more so in case of ante- rior defects where the upper jaw projection is the only reference available to surgeons for plate adaptation; and Abstract Introduction Mandibular reconstruction is often challeng- ing. However, the revolution of computer-assisted design and computer-assisted manufacturing (CAD/CAM), virtual surgical planning (VSP) and 3D printing technology have changed this notion. Patients and Methods In this article, we have described six case scenarios where various aspects of VSP and 3D printing technology have been utilized for complex man- dibular reconstruction procedures, to provide the patients with the best possible outcome in terms of form, function, and aesthetics. Discussion Virtual planning for tumour resection and fbula osteotomies and 3D printing of cutting guides and stereolith models have changed the face of mandibular * Mehul Saha riya.saha0407@gmail.com Adarsh Kudva adarsh.kudva@manipal.edu Joseph Thomas joseph.plastic@manipal.edu G. Srikanth srikanth.mds@manipal.edu Abhay T. Kamath abhaytaranathk@gmail.com S. M. Abhijith aaastk09@gmail.com 1 Department of Oral and Maxillofacial Surgery, Manipal College of Dental Sciences, Manipal Academy of Higher Education, Manipal, India 2 Department of Plastic Surgery, Kasturba Medical College, Manipal Academy of Higher Education, Manipal, India 3 KMC Hospitals, Manipal Health Enterprises, Ambedkar Circle, Mangalore, India