AMFaces: Advanced Additive Manufacturing of User-Focused Facial Prostheses with Real-Life Colour Appearance

Lead Research Organisation: University of Manchester
Department Name: Electrical and Electronic Engineering

Abstract

Facial prostheses are needed when patients are treated for certain cancers or accidental injuries affecting, for example, the nose, lips, eyes, ears, or skin. The quality of prostheses is naturally very important for patients, both protecting the affected area and giving them confidence, self-esteem, and an improved quality of life.

The demand for facial prostheses is growing rapidly, with increases in cancer rates, an ageing population, and rising patient expectations. Within the UK, there are currently over half a million people with facial disfigurement, and each year about 2,500 new patients need facial prostheses. Compounding the problem, prostheses need to be renewed every 12-18 months as they degrade and discolour.

At present the production of facial prostheses is technically demanding and lengthy, with the end-product depending on the skill of only a few highly experienced maxillofacial prosthetists. Their number is likely to diminish further with 20% of the workforce due to retire over the next 5 years.

A new approach is needed urgently to deliver consistent high-quality prostheses to patients in a timely and cost-effective manner. There are, though, significant challenges. To date, no modern manufacturing method has managed to control medical grade silicone to reproduce facial skin tissue with the necessary softness, colour, surface texture, and flexibility, all in high fidelity. In fact, there is no good computer model for 3D facial skin appearance, even with the latest digital imaging techniques.

To meet these challenges, we have brought together a multidisciplinary team of experts and early career researchers (ECRs) from five universities whose expertise is essential for a successful outcome: clinicians in maxillofacial and oral surgery, scientists and engineers in 3D printing (additive manufacture or AM), reconstructive science, biomaterials, colour science, and imaging. The multidisciplinary nature of this project will allow ECRs to gain broader knowledge, skills, and leadership training in different research areas, mentored by researchers at the forefront of their fields.

Our work entails several innovations:
- introducing 3D hyperspectral imaging and computer modelling of facial skin colour, texture, 3D shape, and translucency for all ethnicities
- developing hybrid AM systems for manufacturing medical silicone parts with micron-level modelling of skin surface colour and texture
- transforming physical modelling data to digital pipeline AM printer control
- formulating new medical silicones and colorants with improved longevity
- maintaining throughout a patient-centred approach, with patient feedback incorporated at every stage of the manufacturing process.

The tight integration of these advances is central to achieving our goal, enabling the prompt delivery of bespoke ultra-realistic facial prostheses on demand.

The results of the research will be delivered mainly through two NHS Foundation Trusts (Manchester University and Guy's and St Thomas', London) and will support regional NHS networks for prosthetic services and charities. We will work with local SMEs to facilitate sustainable research development and further investment. We will share our technological innovations with the clinical, scientific, and engineering communities, especially with developing countries with limited resources.
 
Description 3D scanning service to PhD student 
Organisation Henry Royce Institute
Department Henry Royce Institute – University of Manchester Facilities
Country United Kingdom 
Sector Academic/University 
PI Contribution Se Hun Chung, PDRA at King's College London (KCL), conducted a facial scan on Joseph Lynch, PhD student at the University of Manchester on 2 November 2023 using the Artec Spider 3D scanner funded by the project. Joseph needed the morphology of the outer ear. The scan provided a 3D image of an ear for Joseph to input into the scanner at Manchester.
Collaborator Contribution Joseph agreed to undergo a facial scan which enabled Se Hun to test his developing facial scanning protocol and to make any adjustments to the procedure.
Impact Joseph Lynch presented the image taken at KCL at a Tissue and Cell Engineering Society (TCES) UK - The Society of Life Support Engineering (SLSE) Japan online workshop in a short presentation on 1st February 2024 (https://tces.org/).
Start Year 2023
 
Description EPSRC Engagement Presentation at Manchester Metropolitan University 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Supporters
Results and Impact Overview presentation of AMFaces, the EPSRC awarded project, to the EPSRC Head of Regional Engagement Northwest England and the Portfolio and Senior Portfolio Manager of the EPSRC Manufacturing and the Circular Economy Theme who were visiting Manchester Metropolitan University.
Year(s) Of Engagement Activity 2024
 
Description EPSRC Healthcare Technologies strategy launch 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Prof Harris was invited to present some of our research, particularly including this project, at the EPSRC Health Technologies strategy launch at Manchester's Industry & Science Museum.
Year(s) Of Engagement Activity 2023
 
Description Talk at Friedrich-Alexander-Universität Erlangen-Nürnberg 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Talk and meeting regarding Aerosol Jet Printing
Year(s) Of Engagement Activity 2023