The goal of this five-year research programme, funded by the Engineering and Physical Sciences Research Council, is to enable the delivery of bespoke ultra-realistic facial prostheses to patients in a timely and cost-effective manner using modern digital methods of imaging and manufacture.
Facial prostheses are needed when patients are treated for certain cancers or accidental injuries affecting, for example, the nose, lips, eyes, ears, or skin. The quality of prostheses is naturally very important for patients, both protecting the affected area and giving them confidence, self-esteem, and an improved quality of life.
The demand for facial prostheses is growing rapidly, with increases in cancer rates, an ageing population, and rising patient expectations. Within the UK, there are currently over half a million people who have been affected, and each year about 2,500 new patients need facial prostheses. Compounding the problem, prostheses need to be renewed every 12-18 months as they degrade and discolour.
At present the production of facial prostheses is technically demanding and lengthy, with the end-product depending on the skill of only a few highly experienced maxillofacial prosthetists. Their number is likely to diminish further with 20% of the workforce due to retire over the next five years.
A new approach is needed urgently to deliver consistent high-quality prostheses to patients in a timely and cost-effective manner. There are, though, significant challenges. To date, no modern manufacturing method has managed to control medical grade silicone to reproduce facial skin tissue with the necessary softness, colour, surface texture, and flexibility, all in high fidelity. There is no good computer model for 3D facial skin appearance, even with the latest digital imaging techniques.
Approach to research
We have brought together from five UK universities a multidisciplinary team of experts and early career researchers (ECRs) whose expertise is essential for a successful outcome. They comprise clinicians in maxillofacial and oral surgery and scientists and engineers in 3D printing (additive manufacturing), reconstructive science, biomaterials, colour science, and imaging.
Research vision
This project will enable bespoke ultra-realistic facial prostheses to be developed for individuals affected by cancer, trauma, and congenital defects. It will deliver a new approach to manufacture and improve the quality of life for thousands of patients in the UK and beyond. And it will aid the prompt delivery of bespoke ultra-realistic facial prostheses on demand.
Project outcomes
The results of the research will be delivered mainly through two NHS Foundation Trusts (Manchester University FT and Guy’s and St Thomas’ FT, London) and will support regional NHS networks for prosthetic services and charities. We will work with local SMEs to facilitate sustainable research development and further investment. We will share our technological innovations with the clinical, scientific, and engineering communities, and especially with developing countries with limited resources.
Research themes
Precise computer facial models
Integrated digital 3D representation of the face and head using 3D angular hyperspectral imaging
Novel additive manufacturing systems
Develop a hybrid process using a high-viscosity reactive-jetting printer for volume and a multi-axis aerosol jet printer for micro-features
Biocompatible materials and colourants
Establish baseline characteristics of facial skin populations and to develop high-fidelity test specimens spanning the gamut of skin colours
Product evaluation and quality assessment
Evaluate the mechanical, physical, and colour properties of additive manufactured samples to ensure that they match patient expectations
Public involvement and open science
Using meetings, seminars, and outreach activities to involve patient and support groups
