Reestablishment of quality of life of otoplasty patient with customized substructure and three-dimensional printed ear prosthesis – A novel approach

Auricular abnormalities can majorly impact both beauty and psychological well-being. Traditional prosthetic fabrication procedures are labor-intensive and require specialized knowledge. Advances in digital technologies, particularly three-dimensional (3D) printing, provide affordable and customizable alternatives. Fused deposition modeling (FDM) is one of the more accessible and cost-effective options. Ninjaflex is a flexible thermoplastic polyurethane filament that mimics the supple qualities of human flesh, making it ideal for prosthetic applications. A 72-year-old female with a traumatic auricular defect sought a noninvasive treatment. The contralateral ear was digitally scanned, and computer-aided design software was utilised to generate a mirrored, anatomically correct design. The prosthesis was created with Ninjaflex and an FDM printer. Postprocessing procedures, such as smoothing and airbrushing medical-grade pigments, improved the prosthesis’s appearance and functionality. The patient reported great delight with its appearance and comfort. However, difficulties were encountered in obtaining fine surface details and maintaining long-term durability. This case report highlights the viability of employing Ninjaflex and FDM 3D printing to construct low-cost, patient-specific auricular prostheses. While surface polish and material durability remain issues, this technology provides a quick and easy option for prosthetic production, especially in resource-constrained environments. More material and technical developments are required to optimize results.