by Lucy Ashton
A once highly specialised technology has now become an essential part of modern patient care, as NHS Greater Glasgow and Clyde marks more than 20 years of progress in 3D surgical planning and printing.
Based at the Queen Elizabeth University Hospital in Glasgow, the West of Scotland Regional Maxillofacial and Plastic Surgery Technical Service has transformed how complex surgery is planned and delivered, evolving from a niche, largely outsourced process into a fully embedded part of routine care.
“When we first started, 3D planning was really specialised and it often felt quite distant from day-to-day clinical care,” said Pauline Paul, Consultant Maxillofacial Prosthetist/Clinical (Reconstructive) Scientist and service lead.
“What’s been remarkable over the past 20 years is how it’s become something that clinicians now rely on as part of routine practice.”
In its early stages, the technology was far removed from hospital settings. Imaging data was transferred on to CDs and sent to external providers, with finished models returned days or weeks later. While effective, the process limited flexibility, added cost and kept it at the margins of clinical care.
Over time, that began to change.
Teams in Glasgow started to bring elements of the process in-house, first working directly with imaging data using specialist software, then developing a hybrid approach where surgical planning was carried out locally while printing remained outsourced.
“There wasn’t one defining moment where everything changed,” Pauline added. “It’s been a gradual process of learning, building trust and working closely with clinical teams to understand what’s actually needed to support patients.”
A decisive step came as demand for 3D planning grew and the cost of outsourcing rose significantly. The move to in-house printing allowed the service to become more responsive and better aligned with clinical needs, reducing turnaround times and enabling teams to support urgent and complex cases more effectively.
Today, the service supports a wide range of specialties, including maxillofacial surgery, plastics, neurosurgery, and ear, nose & throat (ENT), providing detailed anatomical models, digital surgical planning, and patient-specific guides.
But those involved say the real story lies in how the technology has been adopted.
“This hasn’t been driven by technology alone,” Pauline said. “It’s been shaped by collaboration – by surgeons, scientists, and technical staff working together, case by case, to refine how we do things.”
That collaborative approach came to the fore during the COVID-19 pandemic, when teams worked across specialties to design and produce 3D-printed protective equipment at pace – demonstrating both the agility of the service and the strength of cross-disciplinary working.
For patients, the impact is increasingly significant.
3D planning allows clinicians to prepare for complex procedures in detail, improving precision in theatre and supporting more predictable outcomes. It can also help patients better understand their treatment, with visual models and plans making procedures easier to explain.
“For patients, it can make a real difference,” Pauline said. “Being able to visualise and plan surgery in such detail helps clinicians deliver more precise care, but it also helps patients understand what’s going to happen and feel more confident about their treatment.”
As surgical cases become more complex, the role of 3D technology continues to grow. What was once reserved for a small number of cases is now used across a broad range of procedures, including craniofacial reconstruction, trauma, and cancer surgery.
That shift – from specialist innovation to everyday tool – is perhaps the most significant change of all.
“What was once innovative is now essential,” Pauline added. “We’re seeing 3D technology used across a growing range of specialties, and it’s continuing to evolve alongside the needs of the patients we serve.”