From scan to scalpel: 3D printing revolutionizes surgery at Charleston

Using advanced 3D printing technology, the facility’s Innovation Center is transforming standard radiological imaging into lifelike anatomical models. These models help surgeons plan complex procedures with greater precision and give Veterans a clearer understanding of their care.

“We’ve created more than 30 anatomical models so far, and we can build for any surgical specialty,” said Nicole Beitenman, Director of the 3D Innovation Center. “As long as we have high-quality imaging, we can turn it into a physical model that helps guide care.”

The process begins with thin-slice CT or MRI scans obtained from Radiology. Once viable imaging is secured, the Innovation Center utilizes segmentation software that is specific to anatomical modeling and collaborates closely with the requesting clinician to tailor the model to their exact needs. “We have an ordering form with specific questions to gather the exact details of what the surgeon is looking for in the model,” Beitenman explained. “After the first design, we send the surgeon a link where they can view and rotate the model in 3D. We can edit in real time with the surgeon to make fine detail adjustments to ensure the model is perfect. From there, it goes to the 3D printer for production.”

The collaboration between the Innovation Center and surgeons has already made a difference in the operating room.

Dr. Paul Womble, a surgeon at the Ralph H. Johnson VA HCS, recalled a case where a 3D model changed the entire surgical approach. A centrally located kidney mass was initially planned for an anterior transperitoneal approach. But the model revealed that the renal vein’s position would obstruct access.

“The model revealed that the renal vein followed an abnormally circuitous path, resulting in limited access to the tumor and an increased complexity and risk of the procedure,” he said. “Because of the model, we switched to a posterior approach,” Womble said. It gave us outstanding exposure and allowed for a successful resection. Without it, we likely would have faced a longer operative time and more complex dissection.”

Womble emphasized that while experienced surgeons can mentally reconstruct anatomy from 2D scans, physical models offer a tangible advantage, especially for residents and patients.

“As physicians, we’re trained to interpret CT scans, but that takes years of experience,” he said. “For patients and younger trainees, having a model they can hold, and study makes a huge difference. It bridges the gap between imaging and understanding.”

In one particularly complex case, Womble used a 3D model to prepare for surgery on a Veteran with a solitary kidney. The model highlighted not only the tumor but also the surrounding vasculature and collecting system.

“It gave me a better sense of the angle of approach and helped me avoid major vessels,” he said. “It also helped the patient understand the complexity of the surgery. Afterward, I offered them the model to take home, and they were thrilled.”

The models are also proving to be powerful tools for education and communication. Womble uses them to teach residents and medical students, offering a hands-on reference during pre-op planning and even in the operating room.

“Having the model in hand provides orientation aids much quicker than reviewing a CT scan mid-surgery,” he said. “It’s a game-changer.”

Each model takes between 12 and 72 hours to complete, depending on complexity. After printing, the Innovation Center team post-processes and cleans the model before delivering it to the clinician. The technology behind the scenes is just as impressive as the results.

“There are only a handful of printers and software systems that can handle this level of detail,” Beitenman said. “But the field is evolving fast. AI is already being integrated into the software to automate segmentation, which will make the process faster and more accessible.”

As the program grows, Beitenman hopes more clinicians will take advantage of the service.

“We’re working to raise awareness,” she said. “The demand is steady, but we know more Veterans could benefit if more providers knew this was available.”

For Womble, the value is clear.

“I’m immensely grateful for Nikki Beitenman and the entire 3D Innovation Center,” he said. “They help us provide the best possible care to our Veterans. This is the future of surgery, and it’s happening right here in Charleston.”