He thought he would have to live the rest of his life with a half-blown face. But technology has decided otherwise. Severely disfigured in an accident, Dave Richards, 75, can go out again without frightening passers-by and his grandchildren. Thanks to a face recreated by 3D printing.
A terrible accident that tears off his face
Dave’s ordeal began in July 2021. While he was out with friends, he was hit by a driver and dragged under the car. His pelvis and ribs are fractured. But it is his face that is most affected: an entire side of his face, his nose, his neck and his skull are torn off. The man suffered third degree burns. Surgeons have no choice but to remove one of his eyes and attach a flap of skin to the damaged half of his face.The decision was then made to go for a free flap, taking tissue containing blood arteries and veins and stitching it into my neck, with the flap completely covering the side of my face.” specifies the victim.
The work is remarkable. Dave Richards is alive. But half of his face is now erased, non-existent.
A prosthesis designed in 3D recreates his face
During his recovery – during which he had to undergo two secondary operations to remove scar tissue from the flap – Dave was then referred to a reconstructive prosthetics center, which had just opened Bristol 3D Medical Centre. It is the first system of its kind in the UK to offer 3D scanning, design and printing of this type in a single NHS site.
Numerous tests and protocols follow. “It’s not the most pleasant process, the grandfather admits today, “they relied on various molds and wax impressions from manual processes, they took a lot of photos to have a record of what it looked like, and there was a lot of work to do to make the molds and casts on my face covering my nose and mouth.”
But as part of his treatment, Mr. Richards then receives a 3D prosthetic that adapts to the space of his face and perfectly mimics the color of his hair, eyes and skin. The result is stunning.
The return of his image… and his confidence
The surreal experience bears fruit. “It took me a long time to feel comfortable with my image, with how I thought people looked at me and what they thought of me – but I’ve come a long way in that regard” admits the man today. “I wanted to explore anything that could be done to change the visual aspects of my injuries to give me more confidence.”
Today photographed from every angle, Dave Richards says he is happy. Glad to have gone through this treatment process,
“because he brought me to where I am today.”
The 3D printer, the future of reconstruction?
If the face reconstructed in 3D printing is today a first, the technique could well heal as many bones and skin as wounds to the soul in accident victims.
“When 3D capability came along, it opened up a whole range of possibilities.” admits Amy Davey, senior reconstruction scientist at NBT. In this new center, the 3D printers used use advanced plastic resins whose properties allow direct application to the skin, with materials safe for the skin for long periods of time.
“Another printer at the center has the ability to produce materials that closely resemble those of the bones themselves, allowing for a much more “natural” implant. continues the scientist.
Over time, 3D scanning could also quantify a patient’s progress and allow necessary adjustments to be made, including for scar treatment and monitoring. This doesn’t prevent accidents, unfortunately. But if it can rebuild tissues, and a life, why not use it more?