Case Study: King's College Hospital achieves restored facial symmetry and jaw function with Materialise 3D planning and patient-specific titanium plate

Jaw Reconstruction and 3D Planning for Orthognathic Surgery

King’s College Hospital in London treated a 27-year-old man with severe lower‑jaw trauma that left a hypoplastic left mandible, displaced condyle, missing teeth and malocclusion. Working with Materialise, the surgical team used PROPLAN CMF® and 3‑matic® to plan a 3D bimaxillary orthognathic procedure and design a patient‑specific titanium mandibular plate to restore facial symmetry and function.

Materialise (via its daughter company OBL) modeled and manufactured a titanium megaplate and a polyamide positioning guide using 3‑matic® and additive manufacturing (SLM/SLS). The 3D planning—including mirrored reconstruction of the healthy side and planned LeFort I and BSSO movements (3 mm forward, 3 mm left rotation, 1.5 mm down)—improved CT quality by fusing dental scans, validated the surgical plan, enabled precise implant fit and successful plate placement with iliac bone grafting, and achieved restored facial symmetry, Class I occlusion and an aesthetically pleasing functional outcome.

King's College Hospital

Muhanad Hatamleh

Doctor