Authors: Mohammed Dafalla / Editor: Charlotte Davies / Codes: / Published: 21/04/2026
3D printing is becoming ubiquitous. You may have a 3D printer, or you may be thinking of ways in which it can be useful. Here are a few thoughts on 3D printing in the emergency department (ED) together with a case study on how it is useful. Do add your tips, resources and suggestions in the comments.
Advantages and Disadvantages to 3D Printing
3D printing can be really useful for low cost, realistic training aids. However, the disadvantages include ongoing running costs, the need to store a relatively large printer, and reliance on specialised software that takes time to learn how to master. In addition, a separate laptop may be needed to install the software on without trust base IT restrictions.
Which Printer?
Desktop 3D printers have become increasingly accessible and offer a practical way for clinical departments to produce low-cost simulation models. When choosing a printer, reliability and simplicity are key. It should be user friendly particularly in settings without technical support. Features such as automatic bed levelling and consistent extrusion is crucial to avoid fail prints.
For procedural trainers such as a lateral canthotomy simulator, fused filament fabrication (FFF/FDM) printers are typically the most suitable due to their affordability and ease of use. PLA filament is widely available, inexpensive, and reliable for printing durable educational models.
Other printers such as resin printers are also available but relatively expensive and require extensive curing after printing.
I am not recommending one brand over another, but Bambu lab in general is very reliable. I choose the bambu P1S because of its amazing features: it is superfast with speed of 20000 mm/s and super accurate at the same time. It works directly from the box. It does not require a technical background, you only have to replace the hot-end (nozzle) every few months, which you can do yourself in five minutes. It also supports multi-colour printing – a supercool feature, which can be very handy when you print colour anatomic stands like a heart with coronary vessels. The cost is around 330 for P1S. If the department is buying, I recommend buying the full combo to get the AMS (automatic material system) for multi-colour printing, however it is optional and you don’t need it for the single colour modules. The P1S combo is approximately 485 480 585 mm and weighs 21.60 kg.
Fig. 1 Chat GPT picture showing the size of the printer with A4 paper for scale (Courtesy of the author)
The printer also has a mobile app – you can print from your phone, monitor the progress of your print live through the printer built-in camera and more.
Fig. 2 Printer mobile app (Courtesy of the author)
How much are the filaments?
Each simulator will cost roughly 15. If we considered a trachy simulator, the cost of PLA filaments will cost around 5. If we add the silicone sheets and other materials the cost will sit between 8-10 per simulator. That is extremely low cost – if you look up the commercial trachy module online, it costs minimum 150-200.
The PLA filaments are available online (like amazon) and other online markets. The cost is normally between 9-13 per kilogram of PLA. One kilo was enough to print 18 lateral canthotomy modules.
How about the software? How do you use it?
I used Nomad Sculpt, a mobile 3D software application that runs on an iPad or tablet with a stylus. Unlike many other 3D programs, Nomad Sculpt does not require high-end hardware. It is free to trial.
Most 3D printers will have linked software that is free to use and very good. You may decide to purchase a laptop just to install the software on, to bypass any trust IT restrictions.
Innovation in Emergency Medicine Case Study
Problem
Lateral canthotomy is a rare but vision-saving emergency procedure used to treat orbital compartment syndrome. Because the condition is uncommon, many emergency medicine trainees have limited opportunities to practice the procedure before encountering it in clinical practice.
Some procedures in emergency medicine are performed every day, others may be needed only once in a career, yet must be performed immediately and correctly when the moment arrives. Lateral canthotomy is one such procedure.
Orbital compartment syndrome is a time critical emergency most commonly caused by a retro-orbital hemorrhage following trauma. Rising pressure within the confined orbital space can rapidly compromise retinal and optic nerve perfusion, potentially leading to permanent vision loss. Emergency decompression through lateral canthotomy and cantholysis may therefore be required before specialist ophthalmology input is available.
Despite its importance many clinicians have limited opportunities to practice this procedure during training. simulation therefore plays a key role in developing confidence and procedural competence.
To improve accessibility to procedural training, a low-cost 3D printed lateral canthotomy simulation model was developed for emergency medicine teaching.
Innovation
A low-cost lateral canthotomy simulator was developed using desktop 3D printing. The model incorporates a 3D printed orbital base, silicon-like skin layer, rubber bands representing the canthal tendons and artificial eyelashes to improve visual realism.
Cost and accessibility
Each model takes approximately two hours to print and costs around 2.13 in total (if you already have a printer) making it feasible to produce multiple trainers for teaching sessions.
Impact
The model has already been used in our trusts monthly teaching sessions for emergency medicine trainees/SAS doctors and has received excellent feedback, improving both anatomical understanding and procedural confidence.
Development of the model
The simulator was designed using Nomad Sculpt V2.8 – A 3D modelling software (Fig.3) and produced using a Bambu Lab P1S 3D printer with PLA filament. The printed structure forms the sliced half skull, the model represents the hard part of the orbital anatomy (Fig. 4).
Fig. 3 – Design with Nomad Sculpt 2.8 (Courtesy of the author)
Fig. 4 – Bambu Lab slicer and cost (Courtesy of the author)
To simulate soft tissue layers and anatomical structures additional low-cost materials were incorporated into the design. A skin-like silicone sheet is cut to shape of the printed part, making sure to cut an elliptical shape for the eyeball. Rubber bands are positioned to simulate the superior and inferior limbs of the lateral canthal tendon, allowing trainees to identify and divide the structures during the procedure. The silicone sheet then laid over the printed structure to represent facial skin and soft tissue. This was partially glued at the model edge for further stability. Artificial eyelashes are added to improve visual realism and anatomical orientation. See Fig. 5 for the material used and Fig. 6 for the final model design.
This layered approach allows learners to experience the key procedural steps involved in lateral canthotomy and cantholysis while maintaining a simple and reproducible design.
Fig. 5 – Materials used (Courtesy of the author)
Fig. 6 – Final lateral canthotomy model (Courtesy of the author)
Designing the module was very enjoyable, almost like working with clay. However, it required patience and close attention to fine details to produce a precise result. Typically, the designing process begins with a basic sphere, which can then be sculpted into a human face by gradually adding material for features such as the ears, nose, and eyes. Nomad also includes a symmetry function, meaning that when you design one side, such as the right eye, the left eye is automatically mirrored.
After completing the model, I found it more practical to divide the design into a half-skull, as the trainee only needs one side of the face to perform a lateral canthotomy. This approach helps save both time and resources.
Cost and production
A major objective of the project was to ensure the model remained highly affordable. Each simulator requires approximately two hours of printing time with a filament cost of around 1.08 (Fig. 4). When adding the cost of other materials such as silicone sheets, rubber bands and artificial eyelashes, the total cost per unit is approximately 2.13.
This extremely low cost allows departments to produce multiple models for group training sessions without significant financial burden.
Use in teaching
The simulator has already been used in our trust during teaching sessions with emergency medicine trainees/SAS doctors. It allows learners to practice several important procedural steps, including identification of the lateral canthus, performing the initial incision, and locating and dividing the inferior canthal tend, and if indicated the superior canthal tendon (Fig. 7).
Because the silicone layer can be easily replaced, the model can be recycled repeatedly for multiple teaching sessions. The total cost when recycled will drop by 50% adding more to already cost-effective model.
Feedback from trainees has been very positive, with participants reporting improved understanding of the relevant anatomy and increased confidence in performing the procedure.
Fig. 7 – Use in teaching imaged after trainee performed the procedure (Courtesy of the author)
Conclusion
Lateral canthotomy is a rare but potentially sight-saving emergency intervention. clinicians should be prepared to perform this procedure, highlighting the need for accessible and practical training tools. Our low-cost 3D printed lateral canthotomy simulator present a simple and effective solution with a production cost of 2.13 per model, provides an affordable option for procedural training and demonstrates the growing potential of 3D printing technology in emergency medicine education.