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AMFaces: Advanced Additive Manufacturing of User-Focused Facial Prostheses with Real-Life Colour Appearance

AMFaces：以用户为中心的面部假体的先进增材制造，具有真实的色彩外观

基本信息

批准号：
EP/W033968/1
负责人：
David Foster
金额：
$ 706万
依托单位：
University of Manchester
依托单位国家：
英国
项目类别：
Research Grant
财政年份：
2023
资助国家：
英国
起止时间：
2023 至无数据
项目状态：
未结题

来源：
https://gtr.ukri.org/projects?ref=EP%2FW033968%2F1
关键词：
AMFaces Advanced Additive Manufacturing User

项目摘要

Facial prostheses are needed when patients are treated for certain cancers or accidental injuries affecting, for example, the nose, lips, eyes, ears, or skin. The quality of prostheses is naturally very important for patients, both protecting the affected area and giving them confidence, self-esteem, and an improved quality of life. The demand for facial prostheses is growing rapidly, with increases in cancer rates, an ageing population, and rising patient expectations. Within the UK, there are currently over half a million people with facial disfigurement, and each year about 2,500 new patients need facial prostheses. Compounding the problem, prostheses need to be renewed every 12-18 months as they degrade and discolour.At present the production of facial prostheses is technically demanding and lengthy, with the end-product depending on the skill of only a few highly experienced maxillofacial prosthetists. Their number is likely to diminish further with 20% of the workforce due to retire over the next 5 years. A new approach is needed urgently to deliver consistent high-quality prostheses to patients in a timely and cost-effective manner. There are, though, significant challenges. To date, no modern manufacturing method has managed to control medical grade silicone to reproduce facial skin tissue with the necessary softness, colour, surface texture, and flexibility, all in high fidelity. In fact, there is no good computer model for 3D facial skin appearance, even with the latest digital imaging techniques. To meet these challenges, we have brought together a multidisciplinary team of experts and early career researchers (ECRs) from five universities whose expertise is essential for a successful outcome: clinicians in maxillofacial and oral surgery, scientists and engineers in 3D printing (additive manufacture or AM), reconstructive science, biomaterials, colour science, and imaging. The multidisciplinary nature of this project will allow ECRs to gain broader knowledge, skills, and leadership training in different research areas, mentored by researchers at the forefront of their fields.Our work entails several innovations: - introducing 3D hyperspectral imaging and computer modelling of facial skin colour, texture, 3D shape, and translucency for all ethnicities - developing hybrid AM systems for manufacturing medical silicone parts with micron-level modelling of skin surface colour and texture - transforming physical modelling data to digital pipeline AM printer control - formulating new medical silicones and colorants with improved longevity - maintaining throughout a patient-centred approach, with patient feedback incorporated at every stage of the manufacturing process. The tight integration of these advances is central to achieving our goal, enabling the prompt delivery of bespoke ultra-realistic facial prostheses on demand. The results of the research will be delivered mainly through two NHS Foundation Trusts (Manchester University and Guy's and St Thomas', London) and will support regional NHS networks for prosthetic services and charities. We will work with local SMEs to facilitate sustainable research development and further investment. We will share our technological innovations with the clinical, scientific, and engineering communities, especially with developing countries with limited resources.

当患者因某些癌症或意外伤害而接受治疗时，例如鼻子、嘴唇、眼睛、耳朵或皮肤，需要面部假体。假体的质量对患者来说自然非常重要，既保护了受影响的区域，又给了他们信心，自尊和改善的生活质量。随着癌症发病率的增加、人口老龄化和患者期望的提高，对面部假体的需求正在迅速增长。在英国，目前有超过50万人面部毁容，每年约有2,500名新患者需要面部修复。更严重的是，修复体每12-18个月就需要更换一次，因为它们会降解和变色。目前，面部修复体的生产技术要求很高，而且生产时间很长，最终产品仅取决于少数经验丰富的颌面修复师的技能。他们的人数可能会进一步减少，20%的劳动力将在未来5年内退休。迫切需要一种新的方法，以及时和具有成本效益的方式为患者提供一致的高质量假体。不过，也存在重大挑战。到目前为止，还没有现代制造方法能够控制医用级硅胶，以复制具有必要的柔软度，颜色，表面纹理和柔韧性的面部皮肤组织，所有这些都是高保真的。事实上，即使使用最新的数字成像技术，也没有很好的3D面部皮肤外观的计算机模型。为了应对这些挑战，我们汇集了来自五所大学的专家和早期职业研究人员（ECR）的多学科团队，他们的专业知识对于成功的结果至关重要：颌面和口腔外科的临床医生，3D打印（增材制造或AM）的科学家和工程师，重建科学，生物材料，颜色科学和成像。该项目的多学科性质将使ECR获得更广泛的知识，技能和领导力培训，在不同的研究领域，由研究人员在各自领域的前沿指导。我们的工作需要几个创新：- 引入面部皮肤颜色、纹理、3D形状的3D高光谱成像和计算机建模，- 开发用于制造医用硅胶部件的混合增材制造系统，并对皮肤表面颜色和纹理进行微米级建模-将物理建模数据转换为数字管道AM打印机控制-配制具有更长寿命的新型医用有机硅和着色剂-始终保持以患者为中心的方法，并将患者反馈纳入制造过程的每个阶段。这些进步的紧密结合是实现我们目标的核心，能够按需迅速交付定制的超逼真面部假体。研究结果将主要通过两个NHS基金会信托基金（曼彻斯特大学和伦敦的Guy's and St Pennas '）提供，并将支持区域NHS假肢服务和慈善机构网络。我们会与本地中小企业合作，促进可持续的研究发展和进一步的投资。我们将与临床、科学和工程界，特别是资源有限的发展中国家分享我们的技术创新。