Apr. 20, 2015 | By Alec

While 3D printing technology has proven capable of manufacturing fantastic and affordably prosthetics already, most of these prostheses are very recognizable as such. After all, they tend to be voluminous PLA grippers 3D printed in bright colors. But 74-year-old skin cancer survivor Keith Lonsdale shows that these 3D printed prosthetics can also blend right in. He was recently given a 3D printed face prosthesis to cover up the large hole in his face left by the necessary surgery. To ensure a good look, his son was the model.

Keith’s story really reflects the horrors of cancer. As he explained to reporters, the granddad first went to the docot’rs for a small facial mark in 1990. It turned out to be a basal cell carcinoma that had spread to the non-smoker’s nose, mouth and cheek. ‘It was a huge shock but I did what I had to do and had ­radiation therapy for an hour-a-day every day for two weeks,’ Keith said, and his wife Marjorie did everything to support him.

Fortunately, this was quite a success. After three months of procedures, he was declared cancer three. But then 14 years later, in 2004, he began to display more symptoms. ‘It was quite a shock at first but I knew it must be the cancer. Eventually it swelled right up and I went back to the doctors. It had come back in three places and I was told they would have to take a bit of my face away,’ Keith said. Eventually, surgeons from the University Hospital in Nottingham removed Keith’s nose, cheekbones, upper jaw and most of his palate. All in all, the former train driver underwent dozens of operations. This grueling procedure left Keith without any bones under his eyes and a huge gaping hole in his face. To make things worse, this made eating, drinking and even breathing very difficult.

Fortunately, he was referred to reconstructive scientist Jason Watson at Nottingham’s Queen’s Medical Centre soon afterwards, who developed a series of prosthetic masks for Keith. Unfortunately, none of these were quite good. As his wife recalled, they made him look very strange and needed to be glued on again and again. ‘It was developed quickly but it was nowhere near what he looked like. And it wasn’t long enough on his top lip. His nose wasn’t the same either. His own nose was much thinner and it wasn’t pointed,’ she said.

To make things worse, the glue often wore off during the day, so Keith carried a piece of elastic around with him whenever he went out. ‘It was a bit of a struggle,’ said Keith. ‘If I noticed things were going wrong when I was out I’d quickly put it on so I could get home.’ Subsequent masks were similarly problematic, making the whole thing a great ordeal. Keith lost all self-esteem and became very reluctant to leave the house at all. ‘I didn’t go out ­anywhere because I’d get food between my teeth and coming out my nose. Drinking was always the worst,’ Keith said.

Father and son.

The family, which includes eight grandchildren, began looking for ways to get a mask that looked just like Keith’s former face and give him back some of his self-esteem. And earlier this year, the breakthrough came thanks to 3D printing technology. Reconstructive scientist Jason suggested scanning the face of a close family member as a basis for the mask, and 43-year-old son Scott proved to be a perfect candidate as he resembled his father quite closely. As Scott said, he was happy to help. ‘I jumped at the chance to help dad because I know how much he’s been through.’

During a six hour procedure, Scott was scanned and images of his father and him blended together to create a new face mask. This was then 3D printed as a mold and used to make a silicone mask. The result is a life-like mask, that even features a fool-proof way of attaching it: a series of magnets embedded into Keith’s face. According to the reconstructive surgeon, this was the first time this type of prosthesis was made using a family member as a model. ‘The ­process of rebuilding Keith’s face was unique in many ways but this was certainly the first time we’ve created a prosthesis based on a family resemblance,’ he said.

The operation was a complete success and Keith is absolutely delighted. ‘Scott has always been a good lad and would do anything for me or his mum and it really is thanks to him that the surgeons have finally been able to get it right. It’s a huge relief to finally get the mask right so that it fits properly and looks right.’ As the mask fits properly, making eating and drinking easier, and doesn’t fall of his face all the time, it has given Keith a lot more confidence and enjoyment again. It’s even difficult to drag him out of the pub again. 

 

 

Posted in 3D Printer Applications

 

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Anonymous wrote at 7/27/2017 9:02:04 AM:

Oh this made me cry! You are an inspiration!! :'-)

tina boley huey wrote at 9/15/2016 12:10:53 PM:

sir your amazing

M.D. wrote at 4/21/2015 6:13:16 PM:

Donation for clinical research of skin recovery. Even a little investment will be a great help in what we do.



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