Development of a process for cranioplasty using SLS additive manufacturing with AI-assisted modeling

• Grant number: 25/07368-0
• Support Opportunities: Research Grants - Innovative Research in Small Business - PIPE
• Start date: October 01, 2025
• End date: September 30, 2027
• Field of knowledge: Interdisciplinary Subjects
• Principal Investigator: Thiago Nunes Palhares
• Grantee: Thiago Nunes Palhares
• Principal investigators: Pedro Henrique Moreira de Freitas
• Associated research grant: 23/14057-6 - Custom cranial medical prosthesis modeling software assisted by Artificial Intelligence for 3D Printing, AP.PIPE
• Associated scholarship(s): 25/21098-6 - AI-assisted software enhancement for the design and fabrication of molds and cranial prostheses for cranioplasty, BP.TT; 25/21744-5 - Development and optimization of the SLS printing process for manufacturing custom cranioplasty molds, BP.TT; 25/21342-4 - Development of a process for cranioplasty via SLS additive manufacturing with AI-assisted modeling, BP.PIPE

Abstract

Cranioplasty, a critical procedure for cranial reconstruction following decompressive craniectomies, faces major challenges in terms of personalization, efficiency, and accessibility. Traumatic brain injuries, cerebral hemorrhages, extensive strokes, and tumors are among the most common causes leading to this procedure, which involves removing part of the skull to relieve intracranial pressure and save lives. Each year, approximately 3,000 Brazilians undergo this surgery, with around 2,000 requiring a second procedure to repair the resulting cranial defect-highlighting the urgent need for efficient and cost-effective technological solutions. This project aims to develop and validate a low-cost "cranioplasty kit" for cranial reconstruction, combining additive manufacturing and artificial intelligence (AI) technologies. The solution includes a 3D modeling software that uses AI to interpret CT scans, segment anatomical structures, and design patient-specific implants with high anatomical accuracy, reduced processing time, and improved accessibility. The molds for the implants will be produced using selective laser sintering (SLS) with PA12, while the final prostheses will be made from polymethyl methacrylate (PMMA), known for its mechanical strength and biocompatibility. The project seeks to demonstrate the safety and efficiency of the system, ensuring compliance with regulatory standards. This initiative is expected to deliver an innovative and accessible solution, advancing technology in the field of cranial reconstruction. In addition to democratizing access to personalized medical devices, the developed technology holds commercial potential in both Brazilian and international markets, fostering innovation in the healthcare sector. To enhance the impact and reach of this project, we will count on the support and collaboration of the Renato Archer Information Technology Center (CTI), renowned for its expertise in advanced technology research and 3D printing solutions. (AU)