A PIONEERING start-up company which uses three-dimensional printing to produce precise copies of body parts for hospitals is expanding as more and more surgeons become familiar with the technology.

Founded in 2012, Replica 3dm is now used by 21 hospital trusts throughout the UK – helping surgeons to pre-plan their time in theatre.

Its managing director, Matthew Sherry, who lives in Downton, came up with the idea for the business after watching a YouTube video about a 3D printer making an adjustable spanner.

He said: “It’s been a quiet start because we are trying to introduce surgeons to the technology.

“While maxillofacial surgeons have been using 3D printing since 2002 – 3D printing has been around since the late 1980s – it is only in the last five years that it has become more commercially available.

“A lot of people know what it is now and surgeons in other fields, such as orthopaedics, neurosurgery and plastic, are becoming more aware of the benefits.”

Only used in extreme cases, such as a cancerous tumour in the jawbone, surgeons familiar with 3D printing will first transfer CT scan data of the patient to Replica 3dm.

The company then uses different types of software to reconstruct that to a 3D shape before isolating the section the surgeon is interested in and sending the surgeon a quote and a PDF of the 3D image.

Once confirmed it is printed according to when the surgery is scheduled, the models being sold to the NHS at three-quarters of the commercial rate – one of the largest models of a cranium is around £300.

With a background in computer science, Mr Sherry has written elements of computer code in order to enhance the detail of individual bones taken from CT scans and has also designed one of the printers used to produce Polylactic acid (PLA) models – a much cheaper build material.

He said: “Having a 3D model helps reduce surgery time and theatre costs because of the optimal surgical planning which can take place.

“For example, in the case of a patient requiring titanium plates to secure a jawbone following a trauma or a cancerous tumour, the surgeon can pre-bend the plates on the model enabling them to know exactly where to make cuts in theatre.

“There are no surprises and everyone knows what is coming next so they can prepare the instruments required.

“It also means smaller incisions and, due to the quicker recovery time, patient care is improved.”

Salisbury NHS Foundation Trust was quick to recognise the value of the business, providing much of the initial investment – the two main Stratasys printers cost £34,000 each – and at the start was a 33 per cent shareholder.

Following investment from city venture capitalists, the trust has reduced its shareholding to 22 per cent.

“I think we are leading the way on this side of things – in Europe and the United States, 3D printing is predominantly used for maxillofacial surgery, whereas we are trying to pioneer it in different aspects of surgery where we think it makes a big difference,” Mr Sherry said. “It’s growing – I’ll do talks at medical conventions, such as an upcoming event by the Royal Society of Medicine, on how it is revolutionising surgery.”

While 95 per cent of its work is medical, the company also does some commercial commissions such as architectural models.

Currently based on a decommissioned ward at Salisbury District Hospital, Replica 3dm is hoping to move into larger premises on the hospital site soon.