Development of a customised 3D printer as a potential tool for direct printing of patient specific facial prosthesis

Cormac D. Fay, Ali Jeiranikhameneh, Sepidar Sayyar, Sepehr Talebian, Alex Nagle, Kai Cheng, Sophie Fleming, Payal Mukherjee, Gordon G. Wallace

Research output: Contribution to journalArticlepeer-review

6 Citations (Scopus)


This study demonstrates a cost-effective portable fabrication system for 3D printing complex structures from polydimethylsiloxane (PDMS). Material development and characterisation allowed for the design and production of a 3D printer that is capable of fabricating PDMS structures using a photo-initiator and a LED curing process. A 3D model of a participant’s ear was captured using a handheld scanner. These data were used to directly 3D print an ear. Micro-extrusion direct deposition of PDMS at room temperature is demonstrated via a custom designed 3D printer, with in situ UV cross-linking to facilitate curing of the PDMS during the 3D printing process. This 3D printer has great potential to be used as a fast and facile fabrication approach to create facial and other prosthesis. Future developments will also focus on other application areas such as microfluidics, flexible electronics, and other biomedical applications.
Original languageEnglish
Pages (from-to)7143-7155
Number of pages13
JournalInternational Journal of Advanced Manufacturing Technology
Issue number11-12
Publication statusPublished - Jun 2022
Externally publishedYes

Bibliographical note

Copyright the Author(s) 2022. Version archived for private and non-commercial use with the permission of the author/s and according to publisher conditions. For further rights please contact the publisher.


  • Silicone
  • Prosthesis
  • Ear
  • 3D printing
  • Photo cross-linking
  • 3D scan


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