Facial Reconstruction
A Digital Modeling Approach

A surgical team reached out to my colleague (Andrew Grosvenor) and I, seeking a more accurate approach to an out of the ordinary patient case. A patient's nose had been bitten off, and in cases like this, surgeons typically rebuild the nose using tissue from the forehead, carefully shaping it to restore both form and function.

Traditionally, this process relies heavily on surgical expertise and intuition. Surgeons estimate the size and shape of the tissue needed, often using simple materials to map out the reconstruction. While effective, it leaves little room for precision in replicating a patient’s original appearance.

We began by gathering pre-injury photographs of the patient, using multiple angles to reconstruct a digital reference of his original nose. These images were brought into a 3D environment, where they were aligned and used as a guide to carefully sculpt a target outcome, restoring what had been lost as faithfully as possible. A 3D print was produced, facilitating discussion with the patient and planning with the surgeon. 

With both the current anatomy and the desired form modeled in 3D, we were able to define the exact difference between the two.

By subtracting the existing structure from the reconstructed form, we generated an accurate geometry representation for the tissue required for the procedure. This geometry was then translated into a flat, printable cutting guide - providing the surgeon with a clear, accurate template to follow during reconstruction.

The result was a bridge between surgical expertise and digital precision.

Some time after the procedure, there was a knock on the lab door.

A patient stood there and asked if I had worked on his nose. It took a moment to realize - it was him. The reconstruction was so successful that it wasn’t immediately obvious.

He shared something that stuck: no one asked him what had happened to his nose anymore. Instead, they asked about his forehead - where the donor tissue had come from.

The outcome spoke for itself. By combining surgical skill with a thoughtful, technology-driven approach, we were able to restore not just physical form, but a sense of normalcy that made the injury almost invisible.