MedScan3D: Patient-Specific Anatomical Models via 3D Printing

Surgical planning has advanced significantly in recent years, largely driven by new technologies in the medical field. Clinicians now rely on digital tools to create personalized 3D visualizations of pathologies, improving preoperative understanding and helping to reduce intraoperative surprises. Additive manufacturing (3D printing) plays a central role in this evolution by producing patient-specific anatomical models from medical scans. These tangible models allow surgeons to visualize, handle and rehearse procedures before entering the operating room. One company specializing in these models is MedScan3D, which offers a range of 3D-printed products designed to enhance surgical procedures and support the education of healthcare professionals and medical students. We spoke with founder and CEO Jacqui O’Connor to learn more about these devices and how additive manufacturing is applied in clinical and research settings.

3DN: Can you introduce yourself?

My name is Jacqui O’Connor. I am the founder and CEO of MedScan3D. I hold a degree in chemistry and a master’s in biomedical engineering, and my background combines biomaterials research, medical device development and extensive clinical experience within healthcare. I am active in the Irish professional network and support women pursuing careers in STEM. At MedScan3D, we use additive manufacturing to create clinically relevant, patient-specific anatomical models for surgical planning and device testing.

3DN: What is MedScan3D?

MedScan3D specializes in high-fidelity, patient-specific 3D-printed anatomical models derived from CT, MRI and CBCT scans. Our clients include cardiologists, oncologists, and a wide range of surgeons. By putting a patient’s actual anatomy into the hands of clinicians, these models reduce risk, improve surgical outcomes and decrease the chance of unexpected problems in the operating room. In addition to surgical planning, the models are valuable for training staff and explaining procedures to patients.

Our models are not limited to preoperative planning. Engineers and medical device researchers use them as test fixtures and prototyping platforms. MedScan3D produces models in a variety of materials to suit prototyping and device testing needs. These customizable medical models are tailored to specific use cases, helping to optimize test protocols at every stage of device development. Building the right test model is crucial to refine an implant or device so that surgeons have the appropriate tool when treating a particular patient.

MedScan3D simplifies what can otherwise be a complex process by offering a turnkey, fully in-house solution. This end-to-end approach enables rapid production of customizable, patient-specific models without long lead times, meeting the demanding schedules of research and development teams. We take pride in our consultative services and in functioning as an extension of R&D teams engaged in device development and clinical innovation.

3DN: Which 3D printing processes and materials do you use?

We predominantly use material jetting (jetting of photopolymer resins), a process where droplets of liquid resin are deposited layer by layer and cured with UV light. For materials, we offer several options:

Tissue-mimicking materials that replicate the mechanical behavior of soft tissues;
Silicone-like materials available in varying Shore hardness to simulate different tissue textures;
Rigid materials for fixtures and mounts, such as polycarbonate-like or acrylic-like resins for structural or demonstration models.

3DN: What are the main advantages of additive manufacturing for medicine and for MedScan3D?

Additive manufacturing delivers several clear benefits in the medical context:

It enables a physical reconstruction of a patient’s scan, giving clinicians a true 3D model rather than relying on 2D images or screen-based renderings alone.
It supports rapid prototyping to select the right devices and implants before surgery.
It enhances procedural planning through the use of patient-specific models, improving confidence and precision in the operating room.
It improves communication with patients and multidisciplinary teams by providing a tactile reference for anatomical structures and planned interventions.

3DN: How do you envision medical additive manufacturing in 10 years?

The potential for 3D printing in medicine is vast and still largely untapped. At MedScan3D, our goal is to be an integral part of the ecosystem for testing medical devices on anatomically accurate models. We can already supply patient-specific data for bench testing, giving surgeons realistic feedback on devices intended for a particular individual. Advances in bioprinting are particularly exciting, as are developments that allow printed components to replace machined parts while delivering comparable performance. Over the next decade, wider clinical adoption, improved materials and streamlined workflows should make patient-specific models a routine part of preoperative planning and device validation.

3DN: Final thoughts for our readers?

As a woman working in a male-dominated industry, I encourage young women to explore STEM early and to see it as a rewarding field that blends logical problem solving with creative design. Although additive manufacturing remains male-dominated today, women in STEM have the opportunity to lead and to set standards for the next generation. Seek out mentors and peers who inspire and support you—being part of a community helps sustain motivation and drives success. Never let anyone tell you that you cannot achieve the goals you set for yourself. For more information about MedScan3D, search for MedScan3D to find official resources and company details.

*Photo credits: MedScan3D

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