3D-printed facial prosthesis: A 75-year-old cyclist who suffered full-thickness burns to his face when a drunk driver ploughed into his group ride has been fitted with a 3D-printed facial prosthesis in England, The Guardian reported.
Dave Richards received the custom device, matched to his hair, eye and skin tone, after extensive reconstruction, including the removal of one eye to prevent a sight-threatening infection from spreading to his brain.
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Richards was riding with friends in July 2021 when a speeding motorist, over the drink-drive limit and reportedly on his phone, struck the group. Two riders were thrown clear; Richards was trapped beneath the vehicle, suffering third-degree burns to his head and severe injuries to his back, pelvis and ribs. “I was lucky to survive,” he told The Guardian, recalling how the car’s engine and exhaust burned one side of his body while the other was crushed.
During recovery, he was referred to the reconstructive prosthetics team at North Bristol NHS Trust, which has opened the Bristol 3D Medical Centre, the first NHS site in the UK to bring 3D scanning, digital design and printing under one roof. Surgeons performed a free-flap procedure, transplanting tissue with its own blood supply to cover the damaged side of his face before creating a bespoke prosthesis.
Senior reconstructive scientist Amy Davey said the clinic’s motion-tolerant surface scanning helps prostheses accommodate natural facial movement, while new skin-safe resins allow devices to be worn for long periods. Richards admitted the process was “not the most pleasant” and early on he avoided social situations, but said the result has helped him regain confidence. “I’m glad I followed this treatment process as it has got me to where I am today,” he said, The Guardian reported.