A 75-year-old cyclist named Dave Richards suffered a horrific accident in 2021 when a drunk driver crashed into him while he was cycling.
The crash caused severe injuries including a broken back, multiple fractures in his ribs and pelvis, and full-thickness burns to the side of his face affecting his eye, nose, and neck. Due to the severity of his facial wounds and the risk of infection spreading to his brain, doctors made the difficult decision to remove his injured eye.
Dave’s recovery journey took a remarkable turn thanks to pioneering surgery combined with cutting-edge 3D printing technology. He became the first patient to benefit from the NHS’s newly established Bristol 3D Medical Centre, the UK’s first facility to offer integrated 3D scanning, design, and printing for facial reconstruction. Specialists created a custom 3D-printed prosthetic face for Dave that mimics his natural skin tone, hair color, and eye color to fill in the facial areas lost to injury.
Before receiving the prosthetic, Dave underwent a free flap procedure, where tissue along with arteries and veins was microsurgically transplanted from his neck to cover and rebuild the affected area on his face. This surgery, coupled with follow-up operations to release scar tissue, was a success and greatly improved both function and appearance.
Despite early feelings of vulnerability and social withdrawal due to his disfigurement, Dave credits the 3D prosthetic with restoring his confidence and helping him reengage socially. The innovative use of 3D technology represents a major advance in reconstructive medicine, enabling patients with severe injuries to not only survive but regain a realistic, personalized facial appearance.