3D printed models can guide safe halo pin placement in patients with diastrophic dysplasia.

To trial the use of three-dimensional (3D) printed skull models to guide safe pin placement in two patients with diastrophic dysplasia (DTD) requiring prolonged pre-fusion halo-gravity traction (HGT). Two sisters aged 8 (ML) and 4 (BL) with DTD were planned for staged fusion for progressive kyphoscoliosis. Both sisters were admitted for pre-fusion HGT. Models of their skulls were generated from computer tomography (CT) scans using Mimics Innovation Suite and printed on a Guider II in polylactic acid. The 3D models were cut axially proximal to the skull equator, in-line where pins are usually inserted, allowing identification of the thickest skull portion to guide pin placement. Eight pins were inserted into each patient's skull. Postoperative CT scans demonstrated adequate pin position. Pre-traction Cobb angles were 122° and 128° for ML and BL, improving to 83° and 86° following traction. Duration of HGT was 182 and 238 days for ML and BL. Prior to fusion, both patients returned to theatre twice for exchange of loose pins and there was one incidence of pin site infection. Surgery was performed via a posterior instrumented fusion. Postoperatively, both patients remained in their halos for 3 months. One pin in BL was removed for loosening. Both patients achieved fusion union by 9 months. 3D models of the skull can be a useful tool to guide safe pin placement in patients with skeletal dysplasias, who require prolonged pre-fusion HGT for severe deformity correction.