3D Printing of Biomimetic Anatomical Replicas for Surgical Planning and Training of Tooth Removal

Tooth removal – particularly third molar extraction – is one of the most common procedures in dentistry and can lead to complications such as damage to adjacent teeth or jaw fracture if not well planned or performed.

Current surgical training relies heavily on cadaver-based models, which present environmental, ethical and handling challenges. Existing 3D printed models offer an alternative but are limited in their ability to accurately replicate both soft and hard dental tissues, reducing their effectiveness for realistic surgical simulation.

Fusetec 3D, an Australian medical training device manufacturer, is collaborating with Adelaide University to develop a new biomimetic approach to dental surgical planning and training. The 15-month project integrates clinical imaging with CAD modelling and additive manufacturing to create realistic, multi-material dental models that better represent patient-specific anatomy.

The research will combine digital design, multi-material 3D printing and mechanical testing to replicate both structure and behaviour of real teeth, bone and soft tissue. It will also establish fracture force testing thresholds and validated finite element analysis (FEA) models to simulate tooth removal procedures with greater accuracy.

By advancing the technology to Manufacturing Readiness Level (MRL) 7, the project will deliver 3D printed models as a scalable alternative to cadaver-based training. These models will support more consistent, accessible and sustainable surgical training, while improving procedure planning and ultimately contributing to better oral health outcomes.