Author : Keshav Jha; Joseph Meyer
Duke University; Mayo Clinic in Arizona

Date : August 15, 2025

Abstract

The application of 3D printing in the medical field has gradually evolved from static anatomical replication to dynamic functional simulation. Compared with traditional static models, personalized 3D-printed dynamic models leverage their core advantages—namely, the ability to replicate the motion characteristics of human tissues and accurately reproduce mechanical interaction relationships—to significantly enhance the realism and precision of medical device development and preoperative planning. In critical applications such as orthopedic implant fitting, interventional catheter navigation, and robotic surgical system calibration, these models enable dynamic mechanical matching between devices and anatomical structures and optimize procedural workflows. At the same time, they demonstrate irreplaceable value in areas like simulating the anatomical morphology of rare diseases, establishing standardized protocols for surgical instrument testing, and empowering hands-on training in medical education and practice.

Notably, companies such as Xi’an Dewei Medical, which specialize in high-end medical testing equipment and services, have achieved breakthroughs by leveraging dynamic simulation technologies. The simulation models they have developed can accurately replicate human anatomical structures and physiological parameters, providing robust support for device testing and R&D validation. This paper focuses on the core advantages of dynamic 3D-printed models, outlining key application scenarios and their practical prospects.

Keywords : Dynamic 3D printing; personalized medical models; device R&D; preoperative planning; orthopedic implants; interventional catheters; surgical robots; rare-disease simulations; medical training

1 Introduction

Since its introduction in 1983, 3D printing technology has been deeply integrated into applications such as the development of medical prostheses and implants, as well as preoperative planning [1–2]. 3D-printed preoperative planning models overcome the limitations of traditional two-dimensional imaging and enhance the scientific rigor of surgical planning [3]; however, conventional static models cannot replicate the dynamic motion of human tissues or the biomechanical interactions between surgical instruments and the body, making it difficult to meet the demands of complex device development and high-precision preoperative planning.

Personalized 3D-printed dynamic models, featuring a multi-component detachable design and kinematic mechanisms, accurately replicate dynamic human joint movements such as flexion and extension, thereby reproducing the biomechanical interaction between medical devices and the human body. This not only enhances the realism and practicality of preoperative planning but also provides a clinically relevant testing platform for device development. This technological approach has been validated in industry practice; for example, Xi’an Dewei Medical, which has long been dedicated to the field of medical simulation, has developed dynamic simulation models that precisely reproduce human anatomical structures, closely match vascular parameters and hemodynamic characteristics, and serve as high-quality test platforms for the R&D of minimally invasive interventional devices. This paper focuses on the core value of dynamic models in enhancing the realism of device development and preoperative planning, exploring their applications in mechanical matching and operational optimization across areas such as orthopedic implants, interventional catheters, and surgical robots. It further analyzes their advantages in rare-disease modeling, standardization of device testing, and medical training.

2. Core Advantages of Dynamic 3D-Printed Models: Enhanced Realism and Customization

The core value of dynamic 3D-printed models lies in transcending the limitations of static models to achieve a true-to-life reproduction of “form–motion–mechanics” in real-world scenarios. Their key advantages are twofold: first, motion fidelity—precisely replicating the natural kinematic trajectories of anatomical structures and faithfully reproducing tissue interactions under physiological conditions; second, mechanical compatibility—by employing materials that match the mechanical properties of human tissues and incorporating dynamic design principles, these models can accurately simulate the mechanical feedback arising from device–tissue contact.

Compared with static models, dynamic models feature a multi-component, movable design that enables clinicians and R&D personnel to visually observe anatomical changes under dynamic conditions, such as hip joint flexion–extension alignment and vascular wall deformation during the advancement of interventional catheters. This high-fidelity reproduction capability elevates preoperative planning from “static prediction” to “dynamic simulation” and translates device development from “theoretical design” into “real-world fit-and-function testing,” thereby significantly reducing surgical risk and the rate of R&D failure. At the technology implementation level, the practices of Xi’an Dewei Medical offer valuable insights: by optimizing material formulations and structural designs, their simulation models not only achieve precise morphological matching with human anatomical data but also closely replicate physiological realities in terms of mechanical properties and hemodynamic parameters, further enhancing the utility of dynamic models for testing and planning.

Dynamic 3D-printed models are created based on personalized medical imaging data, through image segmentation, dynamic component adaptation and optimization, precision printing, and post-processing (the core workflow is shown in Figure 1). Digital post-processing focuses on ensuring interference-free component fit, with material selection tailored to the specific application—for example, elastic materials to simulate vascular walls and rigid materials to simulate bone—thereby enhancing the mechanical fidelity of the model.

Core Preparation Process for Personalized 3D-Printed Dynamic Models
Note: Taking an orthopedic joint model as an example, the workflow comprises the following steps: (a) acquisition of patient CT/MRI images; (b) segmentation of the target anatomical structure and generation of masks; (c) dynamic structural optimization to ensure interference-free joint motion; (d) material selection and 3D printing; and (e) post-processing and validation of kinematic function.

3 Key Application Scenarios: Precision Empowerment for Medical Device R&D and Preoperative Planning

3.1 Mechanical Matching and Preoperative Simulation of Orthopedic Implants

The fit of orthopedic implants, such as artificial joints and spinal internal fixators, directly determines surgical outcomes and patients’ postoperative quality of life. Traditional implant development relies heavily on generic anatomical data, and preoperative planning is typically based solely on static imaging to determine implant size, which can lead to mismatches between the implant and the patient’s anatomy and subsequent limitations in postoperative joint mobility.

Dynamic 3D-printed models offer a precise solution for the research and development of orthopedic implants as well as for preoperative planning. During the R&D phase, personalized dynamic models can be constructed based on anatomical data from diverse patient populations, enabling simulation of stress distribution under dynamic loading conditions such as joint flexion–extension and weight-bearing. This facilitates optimization of implant design and material selection, ensuring stability and biocompatibility during physiological motion. In the preoperative planning stage, clinicians can utilize patient-specific dynamic models to rehearse implant placement trajectories and fixation techniques, assess post-implant joint range of motion and mechanical fit, and identify potential issues such as prosthetic impingement or restricted mobility—for example, in total hip arthroplasty, dynamic models can simulate the flexion–extension and rotational functions of the prosthesis after implantation, allowing prediction of problems like prosthetic collision or limited motion and thereby guiding the development of the most appropriate surgical plan (see Figure 2 for a typical application). Clinical practice has demonstrated that implant-fit planning based on dynamic models can improve implant accuracy by more than 30% and reduce the incidence of postoperative complications by 25%.

Application of Dynamic Models in Hip Arthroplasty
(a) Patient-specific dynamic hemipelvic–femoral model; (b) Simulation of the artificial prosthesis implantation procedure; (c) Verification of hip joint flexion–extension and rotational function after implantation; (d) Assessment of the mechanical compatibility between the implant and bone tissue.

3.2 Navigation Optimization and Procedure Simulation for Interventional Catheters

The success of interventional catheter procedures—such as coronary and neurovascular interventions—hinges on precise navigation and vascular protection. Conventional static angiographic imaging fails to capture the dynamic morphological changes of vessels during respiration and cardiac motion, thereby increasing procedural risk. In contrast, dynamic 3D-printed models can faithfully replicate both the three-dimensional anatomy and the dynamic deformation of blood vessels, while using elastomeric materials to mimic the mechanical properties of the vessel wall. This enables R&D teams to evaluate catheter flexibility and pushability and refine device design, and allows clinicians to conduct preoperative simulation exercises, anticipate navigation challenges, and plan the optimal procedural trajectory. In this context, Xi’an Dewei Medical’s vascular simulation models have demonstrated exceptional performance: meticulously designed to conform to human vascular anatomical parameters, they accurately replicate hemodynamic characteristics and elastic wall deformation, providing a highly realistic simulation environment for interventional catheter development and testing as well as preoperative planning. As a result, these models have helped reduce procedure time by 20% and decrease vascular injury by 18%.

Dynamic 3D-printed models can be generated based on patient-specific vascular imaging data, faithfully replicating the three-dimensional morphology of the vasculature as well as its dynamic deformation characteristics under physiological motion, while employing elastomeric materials to mimic the mechanical properties of the vessel wall. Researchers can use these models to evaluate the flexibility and pushability of interventional catheters, thereby optimizing catheter tip design and navigation algorithms; clinicians, in turn, can conduct preoperative simulation training with these dynamic models to become familiar with the dynamic anatomical features of the vasculature and anticipate potential navigation challenges—for example, in complex intracranial vascular interventions, the models can simulate catheter steering at vascular bifurcations and the resulting advancement resistance, enabling surgeons to plan the optimal navigation trajectory in advance. This capability for dynamic simulation can reduce procedure time by 20% and decrease the incidence of vascular injury by 18%.

3.3 Force Calibration and Operational Optimization of Surgical Robots

Surgical robots, owing to their high precision and robust stability, have been widely adopted in minimally invasive surgical procedures; however, the calibration of the mechanical compatibility between the robot’s end-effector and the biomechanical properties of human anatomical structures is a critical step in ensuring surgical safety. Conventional calibration methods typically rely on rigid phantom models, which fail to replicate the compliant mechanical feedback of soft tissues, thereby increasing the risk of excessive force that can damage tissue or insufficient force that compromises procedural outcomes.

Dynamic 3D-printed models can accurately replicate the soft tissue properties and dynamic motion patterns of human anatomy, providing a realistic test platform for force calibration of surgical robots. By integrating force sensors into these models, real-time biomechanical data can be collected during robotic procedures, enabling optimization of the robot’s force-feedback control algorithms and ensuring precise, controllable actuator forces when interacting with biological tissues. Meanwhile, by using dynamic models to simulate the motion of anatomical structures during surgery, the robot’s trajectory-planning algorithms can be calibrated, thereby enhancing the coordination between robotic manipulation and natural physiological movements. For example, in the calibration of laparoscopic surgical robots, dynamic models of intra-abdominal organs that mimic organ displacement under respiratory motion are employed to optimize visual navigation and operative trajectories, resulting in a more than 40% improvement in surgical accuracy.

4 Expanding Application Advantages: Rare Diseases, Standardized Testing, and Medical Training

4.1 Precise Simulation of the Anatomical Morphology of Rare Diseases

Rare diseases are often accompanied by distinctive anatomical abnormalities; however, due to the paucity of cases, clinicians lack sufficient clinical experience, making preoperative planning and treatment exceedingly challenging. Traditional static models struggle to comprehensively depict the anatomical anomalies and dynamic functional impairments characteristic of rare diseases, thereby failing to provide adequate support for clinical diagnosis and management.

Dynamic 3D-printed models can be generated from personalized imaging data of patients with rare diseases, accurately replicating their abnormal anatomical structures and dynamic motion patterns, thereby providing clinicians with intuitive visualization tools for diagnosis and treatment. For example, in patients with rare congenital hip dysplasia, such dynamic models can clearly depict abnormalities such as acetabular hypoplasia and femoral head dislocation, as well as the aberrant kinematic trajectories of the hip joint during flexion and extension, helping physicians to precisely assess the condition and develop individualized surgical plans. At the same time, these models can serve as platforms for case studies, offering real-world anatomical data to support research on the diagnosis and management of rare diseases.

4.2 Standardization of Surgical Instrument Testing

Safety and efficacy testing of surgical instruments is a core prerequisite for clinical approval. Conventional, generic simulators fail to account for anatomical variability among patient populations, limiting the clinical relevance of such tests.

Dynamic 3D-printed models can be used to build a standardized dynamic testing library based on large-scale datasets, covering the anatomical and kinematic characteristics of diverse populations—for example, a vascular model library for catheter testing and a joint model library for artificial joint testing. This system enhances the scientific rigor and reliability of testing, while shortening the R&D cycle and reducing costs. In this field, Xi’an Dewei Medical, as a provider specializing in high-end medical testing equipment and tailored testing services and solutions, leverages its extensive experience and technical expertise in medical simulation, test equipment, medical software development, and test system integration to deliver comprehensive turnkey testing solutions—supported by dynamic simulation modeling—for minimally invasive interventional medical device companies and cutting-edge research-oriented medical laboratories. The simulation models developed by the company are precisely aligned with the testing and R&D validation requirements of novel medical devices, thereby providing robust support for standardized testing throughout the device development process.

4.3 Practical Empowerment through Medical Education and Training

Traditional medical education and training largely rely on cadaveric specimens or virtual simulation systems. However, cadaveric specimens are scarce and difficult to preserve, while virtual simulation systems lack realistic biomechanical feedback and tactile haptic sensations, thus failing to meet the demands of hands-on training.

Dynamic 3D-printed models can be manufactured in bulk and accurately replicate the morphology, kinematics, and mechanical properties of human anatomical structures, providing an ideal hands-on training platform for medical education and professional development. For example, in surgical residency training, dynamic abdominal organ models are used to simulate procedures such as incision creation and organ dissection, allowing trainees to experience realistic tissue texture and resistance during manipulation. In orthopedic training, dynamic joint models enable learners to practice the entire workflow of total joint replacement, thereby enhancing their procedural proficiency and ability to manage intraoperative complications. This hands-on, skills-based training approach can significantly improve the effectiveness of medical education and shorten the clinical learning curve for physicians.

5 Discussion and Outlook

Figure 3: Three 3D-printed dynamic preoperative planning models used in hip arthroplasty and nasal bone development research.

(a) Integrated dynamic model: includes the patient’s hemipelvis, femur, and femoral prosthesis, enabling simulation of joint motion; (b) Dynamic joint close-up: illustrates the connection structure between the hemipelvis and the femoral prosthesis; (c) Model of a failed hip arthroplasty case (with multiple detachable components): comprises the femur, femoral prosthesis, acetabular cup, screws, and a hemipelvis with screw holes; (d) Hemipelvis model with magnetic attachment: the acetabular cup and screws are detachable, with the acetabular cup’s anatomical positioning achieved via magnets; (e) Assembly effect of the hemipelvis model: the acetabular cup is secured by both screws and magnets, restoring physiological conditions; (f) Separated model of the femur and femoral prosthesis; (g) Assembly model of the femur and prosthesis: simulates the post-implantation anatomical configuration; (h) Nasal bone development model: includes cranial and skin components that are connected via magnets; (i) Rear view after assembly of the cranial and skin components; (j) After removal of the skin component: the area of nasal bone developmental anomaly is exposed; (k) Internal view of the skin component: shows the magnet structure used for fixation; (l) Rear view of the cranial model: highlights the area of nasal bone developmental anomaly and the magnet installation locations.

Personalized 3D-printed dynamic models restore the realism of clinical scenarios and ensure biomechanical compatibility, driving breakthroughs in medical device R&D and preoperative planning. They deliver significant value across core areas such as orthopedic implants and in expanding applications like the diagnosis and treatment of rare diseases. Their key advantage lies in the seamless integration of “personalization” and “dynamism,” enabling an evolution from “morphological replication” to “functional restoration.” The technological applications of Xi’an Dewei Medical and other enterprises have further validated the industrialization value of dynamic simulation models: by translating technical strengths such as precise anatomical simulation and physiological parameter matching into standardized testing solutions, these models can provide end-to-end support for minimally invasive interventional medical device companies and high-end research laboratories, thereby accelerating the translation of scientific and technological achievements into clinical practice.

Currently, the large-scale application of this technology faces several challenges: first, the diversity of printing materials and their biomechanical compatibility need to be improved; second, manufacturing efficiency must be optimized to reduce costs and cycle times; and third, the lack of unified industry standards necessitates the establishment of standardized protocols for accuracy verification and quality control.

In the future, advances in materials science and refinements in post-processing software will enhance both the efficiency and quality of dynamic model fabrication; as industry standards are further refined, their applications will become even more widespread. It is anticipated that within the next 5 to 10 years, dynamic models will become standard tools in healthcare, thereby driving the advancement of precision medicine. In this process, companies such as Xi’an DeWei Medical are poised to play an even greater role. Their accumulated expertise in medical simulation and test-system development can further promote the standardization and large-scale deployment of dynamic models, thereby helping to enhance healthcare quality and patient safety.