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Maxillofacial surgery

Maxillofacial reconstruction based on CT data

Reconstruction plates, TMJ prostheses, devices for the orbit and midface, guides and splints — made individually from the patient's CT.

Skull model with patient-specific maxillofacial plates
Patient-specific titanium plates on an anatomical model: midface, zygomatic region and mandible
What we manufacture

What Bonabyte manufactures for maxillofacial surgery

Every device is designed from the specific patient's CT and agreed with the surgeon before manufacturing.

Mandibular reconstruction plate with a porous surface

Mandibular reconstruction

Reconstruction plates for autografts, resection and cutting guides.

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Condylar process prosthesis: a PEEK component and a titanium plate

TMJ prosthesis

Patient-specific bipolar joint prosthesis: a mandibular ramus prosthesis and a fossa component.

Zygomatico-orbital complex implant on an anatomical model

Orbit and midface

Orbital and zygomatico-orbital plates, midface implants.

Reconstruction plate on an anatomical mandibular model

Microsurgery

Guides for the fibular flap and trial-fit models of the fragments.

Set of patient-specific orthognathic plates on the model

Splints and guides

Surgical guides, splints and guides for removing a section of bone.

Set of patient-specific orthognathic plates

Orthognathic surgery

Plates for orthognathic surgery, planned from the patient's CT or from STL models of your own plan.

A complex combined construct on an anatomical skull model
Complex cases

Combined constructs — as a single project

The midface, orbit, zygomatic region and mandible are designed in a single coordinate system from the patient's CT.

Visual demonstration

Devices on the anatomy

Zygomatico-orbital complex implant on an anatomical model
Orbit and zygomatico-orbital complex / Defect reconstruction after a fracture
TMJ prosthesis on a skull model
TMJ prosthesis / Joint replacement after resection
Zygomatic implants on an anatomical model
Zygomatic region / Reshaping the facial profile
Orthognathic plates on the model
Orthognathic surgery / Patient-specific plates and splints
Midface reconstruction plate on an anatomical model
Microsurgery / Flap reconstruction based on the digital plan
How a case runs

From CT to the kit in the operating room

CT segmentation: three planes and a 3D reconstruction
01 / CT and segmentation / Anatomically accurate 3D model
Resection and reconstruction planning
02 / Planning / Resection lines, fragment positioning
Device design
03 / Device design / Implants, guides, fixation points
Manufacturing: SLM printing
04 / Manufacturing / After approval by the surgeon
Device kit
05 / Kit to the clinic / Devices, guides, models, screws
Case

Mandibular reconstruction with a fibular flap

De-identified project: resection and reconstruction using a fibular donor bone.

  • Mandibular resection guide
  • Fibular resection guide
  • Patient-specific reconstruction plate
  • Trial-fit models of the jaw and fragments in the planned position
  • Set of fixation screws (Ø2.0, lengths 10–14 mm)
Patient-specific mandibular reconstruction plate on an anatomical model
Reconstruction plate and resection guides — fitted to the patient's anatomy
Materials

VT6 titanium and PEEK: what differs for the surgeon

ParameterTitanium VT6 (Ti-6Al-4V)PEEK
Mechanical strengthHighHigh
Thermal conductivityHighLow (lower risk of heat transfer to tissue)
Potential for bone integrationHigh (porous SLM structures)Low
RadiolucencyRadiopaque, limitations with MRIRadiolucent, convenient follow-up
Intraoperative adjustmentLimitedAvailable if required

VT6 titanium is used for load-bearing zones and osseointegration; PEEK where radiolucency, aesthetics and intraoperative modification matter.

Documents and CT requirements

Download the protocol and materials

A correct CT scan speeds up planning and reduces rework. Download the protocol for this speciality and include a link to the DICOM when you send it.

FAQ

FAQ

Depending on the project, the kit may include a patient-specific reconstruction plate, resection guides for the jaw and the donor bone (for example, the fibula), trial-fit models in the planned position and a set of fixation screws.

Screw positions are planned in zones of dense bone before surgery — this provides a passive fit with no gaps, stability and predictability, together with the minimum necessary surgical access.

VT6 titanium (Ti-6Al-4V) offers strength for load-bearing zones, osseointegration and good radiographic visibility. PEEK offers an elastic modulus closer to bone, radiolucency, aesthetics in visible areas and the option of modification during surgery. The choice depends on the clinical task.

Yes. Our portfolio includes TMJ prostheses, including with a zygomatic component, titanium reconstruction plates, orbital plates, splints and surgical guides.

What you should know

Limits of what is possible

Bonabyte designs and manufactures the device according to the treating physician's plan. Medical decisions are made by the surgeon.

What we can do
  • build a 3D model of the facial skeleton from the CT
  • design a reconstruction plate, an orbital device or a TMJ prosthesis
  • prepare resection guides and orthognathic splints
  • agree the geometry and fixation points with the surgeon
  • manufacture the device once the design is approved
What we cannot determine without the physician and the source data
  • the medical indications for surgery
  • surgical access
  • soft tissue condition
  • the prognosis of the clinical outcome
  • resection volume
  • whether a particular material is acceptable
  • the final fixation method

A complex reconstructive case?

Send us a CT — an engineer will prepare a 3D model, calculate the fixation and propose a kit for your case.

Sources and literature

Further reading on this topic

These publications are provided as a reference for professionals. They relate to the topic of this section and are not a guarantee of the outcome in any particular case; applicability is determined by the treating physician. The list should be reviewed and expanded by a clinical specialist.

  1. Virtual planning and guided surgery in fibular free-flap mandibular reconstruction: a 29-case series. J Craniomaxillofac Surg. 2016. [source]
  2. Assessing the role of virtual surgical planning in mandibular reconstruction with free fibula osteocutaneous graft. 2020. [source]
  3. Kurtz SM, Devine JN. PEEK biomaterials in trauma, orthopedic, and spinal implants. Biomaterials. 2007;28(32):4845–4869. [source]

The information on this website is intended for healthcare professionals and does not constitute medical advice, a public offer or a guarantee of clinical outcome. Bonabyte devices are custom-made medical devices designed for a specific clinical task; their applicability depends on the CT data, the anatomy, the condition of the soft tissues, the surgical access and the operative plan. The final decision on the use of a device is made by the treating physician. Contraindications exist and an individual assessment of the clinical situation is required.