By Mikal Williams, RPSGT, RST, BSBA

Over the past decade, 3D printing has gained significant traction in medicine. Neurodiagnostics, a field that demands precision and customization, has benefitted from these advancements, particularly in sleep medicine and electroencephalogram (EEG). Through patient-specific tools and devices, 3D printing can enhance diagnostic accuracy and treatment efficacy, improving patient experience and clinical outcomes.

3-D Printing Applications in Sleep Medicine

Sleep medicine has benefited from 3D printing advancements, particularly in diagnostics and therapeutic device manufacturing.

Custom CPAP Masks

3D printing can create personalized CPAP masks. A study demonstrated that 3D-printed CPAP masks reduced air leaks and improved patient adherence compared to conventional masks, highlighting their potential to enhance sleep apnea therapy.

3D-Printed Airway Models for Sleep Apnea Evaluation

3D-printed airway models allow clinicians to visualize anatomical obstructions contributing to obstructive sleep apnea. These models help personalize treatment plans, guiding surgical interventions such as mandibular advancement surgery or hypoglossal nerve stimulation.

Personalized Mandibular Advancement Devices

3D printing enables precise customization of mandibular advancement devices (MADs). Studies have indicated that 3D-printed MADs significantly enhance patient adherence and therapeutic outcomes compared to mass-produced devices.

Current Applications in EEG

Conventional EEG equipment can present challenges, particularly in electrode placement and patient comfort. Advances in 3D printing address some of these limitations.

Customized Electrode Caps

Traditional, standardized EEG caps sometimes do not conform well to head shapes, which can lead to poor electrode contact, increased signal noise, and lower data accuracy. 3D-printed electrode caps can be customized for each patient, potentially alleviating these challenges.

ninjaCap: The ninjaCap is a customizable 3D-printed EEG and functional near-infrared spectroscopy headgear developed for neuroimaging applications. Using subject-specific head models, it facilitates precise electrode positioning, reduces motion artifacts, and enhances data quality. Clinical validation studies involving over 500 participants demonstrated that ninjaCap significantly improved EEG and near-infrared spectroscopy signal quality.

Ultracortex Mark IV EEG Headset: The Ultracortex Mark IV is an open-source, 3D-printed EEG headset designed for high-fidelity brainwave recordings. Its adjustable, lightweight frame conforms to individual head shapes, optimizing electrode contact and minimizing discomfort.

Innovative Electrode Designs: 3D printing helps create dry and semi-dry electrodes that eliminate the need for conductive gels. 3D-printed electrodes can enhance EEG recordings by providing stable, low-impedance contact with the scalp.

The Growing Future of 3D Printing

The continuous evolution of 3D printing is expected to bring further advancements in sleep medicine. Potential future applications include:

Bioprinting:

Bioprinting is an advanced form of 3D printing that utilizes bio-inks composed of living cells. It has made significant strides toward developing functional airway tissues and other complex organ structures. These innovations hold potential for regenerative treatments targeting sleep disorders caused by structural airway deficiencies.

Bioprinting for airway reconstruction: One of the most promising applications of bioprinting in sleep medicine is the development of bioengineered airway tissues, which could offer personalized solutions for conditions such as obstructive sleep apnea. For example, Thorsten Walles and his team pioneered the implantation of bioengineered airway tissues in patients, creating tissue designed to replace or repair damaged tracheal sections—highlighting the potential of bioprinting to restore airway function in individuals with severe sleep-breathing disorders.

Functional organ prototypes: Bioprinting is advancing toward the creation of complex organ structures. Wake Forest Institute for Regenerative Medicine has engineered functional organ prototypes, including bioengineered bladders implanted into patients. This research underscores the potential of bioprinting in generating patient-specific tissues, which could pave the way for applications in sleep-related neurodegenerative conditions.

Commercialization of bioprinted tissues: As bioprinting progresses from experimental research to real-world applications, biotechnology companies are leading efforts to commercialize bioprinted tissues for research and therapeutic use. For example, Organovo specializes in designing and developing functional 3-D human tissues using proprietary bioprinting technology. While initially focused on medical research, the company’s long-term goal is to create tissues suitable for surgical therapy and transplantation, potentially offering regenerative treatments for neurodegenerative diseases and airway disorders contributing to sleep dysfunction.

Flexible, Biocompatible Electrodes

3D-printed, flexible electrodes could conform to the scalp, enhancing both comfort and signal acquisition. Researchers have successfully fabricated flexible 3D-printed EEG electrodes using conductive materials, demonstrating their potential in personalized healthcare settings.

3D-Printed Adaptive Sleep Positioning Devices

Future advancements in 3D printing will lead to more personalized, adaptive sleep therapy devices that automatically adjust to reduce airway obstruction in sleep apnea patients. By customizing the fit and function to individual anatomies, 3D-printed devices could enhance comfort and compliance, being effective, noninvasive alternatives to traditional CPAP therapy.

Anatomical Models for Surgical Planning

A review highlighted that 3D-printed models in preoperative planning led to better surgical outcomes in 82% of the analyzed studies. Over 50% of the studies also reported a decrease in operation length—showing a role of 3D-printed anatomical models in enhancing the precision of surgical interventions. This is a growing area for sleep disorders, ultimately contributing to more efficient surgical procedures and improved patient outcomes.

Challenges and Considerations

Despite its immense potential, the adoption of 3D printing in sleep medicine faces several challenges. These include:

• Material biocompatibility: Ensuring that 3D-printed components are safe for prolonged skin contact and medical use remains a key concern.
• Cost and accessibility: While 3D printing can reduce long-term costs, initial investments in hardware and expertise may limit widespread adoption.
• Clinical validation: More large-scale studies are required to validate the effectiveness of 3D-printed neurodiagnostic and sleep medicine tools.
• Regulatory approval: US Food and Drug Administration processes can slow the implementation of 3D-printed medical devices.

Conclusion

Despite the challenges, the momentum behind 3D printing in neurodiagnostics is undeniable. As research and development continue to push the boundaries of what is possible, this technology is poised to become an essential tool in sleep medicine. With its potential to enhance diagnostics, improve treatment efficacy, and personalize patient care, 3D printing is not just an innovation, it is transforming the landscape of modern medicine.

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