Mold

About the product
Prothefab designs and manufactures patient-specific two-part cranioplasty moulds intended for intraoperative fabrication of PMMA (polymethyl methacrylate) cranioplasty implants. After a CT scan, a virtual 3D model of the patient's cranial anatomy is generated and a bespoke implant geometry is designed to match the cranial defect precisely. Using advanced 3D printing, Prothefab produces the corresponding two-part mould, delivered sterile and ready for intraoperative use.

How it works
During surgery, PMMA is molded directly using the patient-specific Prothefab two-part mould to reconstruct the cranial defect. The implant can be adapted intraoperatively to accommodate anatomical variations and surgeon preferences, enabling accurate fit and stable fixation.

Key features

• Precise fit — Patient-specific implants matched to the defect to restore skull contours; suitable for small localized defects to large complex reconstructions.
• Cost indication — Solution available from $300 (price indicator displayed on page).
• Fast turnaround — Manufacturing and shipment within 48h to support surgical planning.

Process and deliverables

• Input: patient CT scan to generate a virtual 3D anatomy model.
• Design: bespoke implant geometry matched to the cranial defect.
• Manufacturing: 3D-printed, sterile two-part mould produced for intraoperative PMMA molding.
• Usage: intraoperative molding of PMMA to create the final cranioplasty implant, with allowance for intraoperative adaptation.

Case studies / Clinical examples

• Frontal cranial defect reconstructions, including cases with open sinuses.
• Hemicraniectomy reconstructions with pre- and post-operative fitting illustrations.

Technical characteristics / specifications

• Product type: patient-specific two-part cranioplasty mould for intraoperative PMMA implant fabrication.
• Final implant material: PMMA formed intraoperatively.
• Mould manufacturing: advanced 3D printing; delivered sterile.
• Input data: CT scan → virtual 3D patient anatomy model.
• Customization: fully patient-specific design for precise defect matching.
• Turnaround time: 48h (manufacturing & shipment).
• Price indicator: from $300.
• Intended use: cranioplasty for a wide range of cranial defects, from small to large/complex.