Ohio State researchers find 3D printed surgical models significantly improve tumor removal rates in head and neck cancer

Researchers at The Ohio State University Comprehensive Cancer Center – James Cancer Hospital and Solove Research Institute (OSUCCC – James) have used patient-specific 3D printed anatomical models to significantly improve complete tumor removal rates in surgeries for bone-invading head and neck cancers, according to a study comparing outcomes across 68 patients.

The research was led by Kyle VanKoevering, MD, an otolaryngologist and medical director of the M4 Lab (Medical Modeling, Materials and Manufacturing Lab) within The Ohio State University College of Engineering. It found that surgeries conducted with 3D printed models achieved complete tumor removal in 92% of cases, compared to 74% for procedures carried out without them.

Head and neck cancers — a category that includes cancers of the throat, mouth, and thyroid — frequently require surgery in anatomically complex areas. This often means tumor boundaries can be difficult to visualize. 

Of the 68 patients treated at the OSUCCC – James, 3D models derived from individual patient imaging were used in 37 surgeries, while the remaining 31 were performed without them.

“As a surgeon, I’ve trained over the years to take all of these two-dimensional pictures and mentally create a 3D roadmap in my head about where all of this anatomy and the tumor are located,” said VanKoevering. “3D printing can give us tangible tools to use in the operating room. The precision of what we take out is critical to ensure we get the whole tumor, but not so much that we’re devastating the patient’s function in the long term and taking out things that don’t need to be removed.”

The approach proved particularly significant for bone-invading tumors.

“This model is especially critical in cancers that have invaded bone, because tumor boundaries are often less visible or palpable,” VanKoevering explained. “Our 3D models are built based on the patient’s actual tumor imaging, so it gives us a much better visual map at the patient’s bedside for removing the cancer as completely as possible while also sparing important structures and tissue to maintain function after surgery.”

Scope for broader application

The study is described as the first to assess whether 3D modeling can improve cancer control outcomes in the operating room, with the research team also examining implications for post-operative quality of life — including speech, chewing, and swallowing function.

“This really sets the stage for larger studies looking at how 3D modeling can enhance surgery planning and precision, not just in the field of head and neck cancer surgery but in other areas that involve bone and soft tissue, like orthopedics,” said Matthew Marquardt, a corresponding author on the study and a student at The Ohio State University College of Medicine.

“Long term, our hope is that this work will enable other surgeons to use this technology across the country to help improve people’s lives and improve cancer outcomes.”