OBJECTIVETo manufacture the individual polyurethane (PUR) auricular framework using the rapid prototyping (RP) technique and to evaluate its feasibility in ear reconstruction.

METHODS3-D models of the patient's auricle were reconstructed according to the computed tomography (CT) data. The supporting and drainage structures were created. Then the individual PUR auricular frameworks were manufactured using RP technique. The frameworks were tested for the fatigue strength and elasticity. The frameworks were also put at the subcutaneous layer of rat. At 1, 2, 4, 8, 12 weeks after operation, the shape of the reconstructed ears was observed and the histological examination was performed.

RESULTSThe PUR framework had good elasticity and a much better fatigue strength than high density polyethylene (HDPE) framework. The shape of reconstructed ear matched the prototype very well. The around tissue grew into the implant pore and adhered tightly to the framework 2 weeks after implantation. Histologic examination showed integrated capsule four weeks later without lymphocytes infiltration. The shape kept very well twelve weeks later.

CONCLUSIONSPUR auricular framework manufactured by the 3D reconstruction and RP techniques has very good shape, intensity and elasticity. It can be selected to replace the autograft of rib cartilage framework.