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Despite the increasing use of 3D printing in orthopedic surgery, there is no established method for the validation of a printed bone model. A printing error could potentially lead to complications, especially when the model is used for surgery planning. We aimed to validate a series of 33 acetabular fractures with a novel method by detailed analysis of model errors. After applying a surface filter on both the patients model and the 3D printed model, a two-step registration consisting of landmark-based pre-registration and ICP-registration, was slightly varied and conducted 100 times, yielding a mean surface deviation and standard deviation for each model surface point. We furthermore showed that more than 30 random ICP-registration points lead to a sufficiently good registration, and that the variation of the pre-registration is small enough to guarantee a stable ICP registration result. Deviations caused by failed registration are unveiled by a large standard deviation of the 100 registration routines. For the fracture series, the mean surface deviation error between the printed model and the patient model was less than 1 mm (median = 0.7 mm; 95% CI = 0.68-0.72 mm). The largest errors were found in areas with remaining support structure material, on printbed-facing model sides and on abrasive surface regions. By visualizing the residual registration error, it was possible to clearly detect surface deviations and to quantify them. Health Sciences EPiC Series in Health Sciences Volume 3, 2019, Pages 11–16 CAOS 2019. The 19th Annual Meeting of the International Society for Computer Assisted Orthopaedic Surgery P. Meere and F. Rodriguez Y Baena (eds.), CAOS 2019 (EPiC Series in Health Sciences, vol. 3), pp. 11–16

A Method for Validation and Error-Quantification of 3D-Printed Models for Acetabulum Fracture Surgery