Custom Surgical Phantom Workflow with Radiographic Compatibility and Haptic Fidelity

This study presents a cost-effective workflow for manufacturing high-fidelity surgical phantoms emphasizing customizability, anatomical accuracy, haptic realism, and imaging compatibility. A human elbow digital model from the Z-Anatomy Atlas was modified using Autodesk Fusion 360 for split-mold fabrication. Bone structures were 3D-printed using polylactic acid (PLA) with 20% gyroid infill to simulate cortical and trabecular bone properties. Soft tissues were cast using room-temperature vulcanizing (RTV) silicone with Shore A5 hardness. Ten surface markers enabled precise spatial registration. The phantom achieved anatomical dimensions within ± 1.14 mm tolerance (mean error: –0.78 mm; 95% CI: –1.93 to 0.36 mm). X-ray imaging produced attenuation profiles closely matching clinical radiographs, though ultrasound performance was limited by silicone acoustic properties. The gyroid infill pattern provided realistic drilling resistance comparable to biological bone. Total manufacturing cost remained below €50 per unit with production time under 24 hours. The integration of 3D printing and silicone molding techniques creates phantoms with realistic haptic feedback, radiographic compatibility, and customization capabilities suitable for surgical training programs and medical device validation studies.