Why 3D Printed Brain Models Are Transforming Neurosurgery — Insights from Maggie Lashutka Ahead of RAPID + TCT 2026

Additive manufacturing is increasingly finding its place in healthcare, enabling the creation of patient-specific anatomical models that give surgeons a deeper understanding of complex cases before they ever enter the operating room. By transforming MRI and other medical imaging data into tangible, life-sized replicas, physicians can visualize tumors, critical structures and potential surgical corridors in ways that traditional scans alone often cannot convey. Ahead of RAPID + TCT 2026, we spoke with Maggie Lashutka, biomedical engineer specializing in additive manufacturing at Ricoh 3D for Healthcare, about how 3D printed brain models are supporting neurosurgical planning and why having one in hand can feel, as one surgeon put it, like “having the answers to a test before taking it.”

3DN: Could you briefly introduce yourself and tell us how you first became involved in additive manufacturing and healthcare applications?

Hi! I’m Maggie Lashutka and I currently work as a biomedical engineer specializing in additive manufacturing at Ricoh 3D for Healthcare, LLC. Before joining Ricoh three years ago, I studied at The Ohio State University, where I worked as an undergraduate researcher in the M4 Lab. That experience first introduced me not only to 3D printing but also to its medical applications, particularly anatomical modeling.

Later, I expanded my research into bioprinting during a fellowship in the Lewis Lab at Harvard University. Through these experiences, I fell in love with the potential of additive manufacturing to support personalized care. Seeing how patient-specific models can improve surgical planning and ultimately benefit patients is what continues to motivate me in this field.

3DN: Patient-specific anatomical models are becoming an increasingly important tool in medicine. How is additive manufacturing helping surgeons better understand complex anatomy before entering the operating room?

One surgeon we worked with described having an anatomical model as “having the answers to a test before taking it.” Patient-specific models allow physicians to view and even practice on a life-sized replica of a patient’s anatomy, which can significantly improve surgical preparation by helping them map out the best course of action before entering the operating room.

In this particular case, having a physical model of the patient’s brain allowed the surgical team to see exactly how the tumor intersected with surrounding anatomy. The inclusion of DTI tracts made it possible to visualize key functional pathways and determine where incisions could be made while minimizing disruption to brain activity.

According to medical professionals who utilized this model, including Smruti Mahapatra (medical student at Ochsner Health) and Dr. Michelle Miller (resident neurosurgeon at Ochsner Health), these models improve understanding of tumor location, vascular anatomy and cranial nerve relationships, particularly in complex skull base and intracranial cases. Surgeons reported that the models helped confirm planned operative approaches, identify potential surgical corridors and better appreciate the extent and orientation of lesions. In some instances, they even prompted surgeons to reconsider their approach after revealing anatomical constraints that were not immediately apparent from imaging alone.

The models also serve as valuable teaching tools for trainees by providing a clear three-dimensional view of complex anatomy. Features such as color-coded structures and hollow internal visualization further enhance the ability to study critical neurovascular relationships and tumor boundaries prior to entering the operating room.

3DN: In many surgical cases, physicians rely primarily on medical imaging. What made this particular brain tumor case one where a physical 3D printed model provided additional value beyond scans alone?

When planning surgery for a complicated brain tumor, being able to hold a 1:1-scale anatomical model and discuss it with colleagues can be extremely valuable. Being able to touch, examine and even practice the procedure on something tangible and life-sized can offer physicians greater understanding and confidence before surgery.

Dr. Michelle Miller of Ochsner Health explained that the model was used directly during surgical planning:

“I brought it over when Dr. Marcus Ware, attending neurosurgeon, was planning his trajectory on the stealth machine and referenced it as we discussed how to optimize the trajectory, and he continued to make some adjustments. On a resident level, it was very helpful to conceptualize the different trajectories and the proximity of the tumor to key anatomic structures.”

In this particular case, the tumor was located deep in the left intraventricular region and surrounded by critical structures, including the optic radiations, corticospinal tract, language pathways, ventricles and major venous anatomy. Multiple neurosurgeons initially proposed different surgical approaches based on imaging alone.

By translating MRI and DTI data into a tangible, color-coded 1:1 model, the team was able to better visualize the spatial relationship between the tumor and surrounding functional tracts. This ultimately helped refine the surgical corridor and increased confidence in the final operative plan before entering the operating room.

3DN: The anatomy was segmented using DTI MRI data before being printed. Could you walk us through the workflow of transforming medical imaging into a printable anatomical model?

After a patient is imaged at the hospital, physicians who would like a model send their scans directly to us through our case management portal. In this case, a DTI MRI scan was used, which highlights soft tissue structures as well as important neural tracts associated with brain activity.

From there, segmentation software is used to isolate each anatomical structure from the imaging data so that they can be printed separately and assigned different colors. Segmentation can involve manually tracing structures along the imaging slices or using thresholding tools when certain anatomy contrasts clearly with surrounding tissue.

For complex cases like this one, physician collaboration is critical. Their expertise helps identify important anatomical features that may not always be clearly visible in the imaging data.

3DN: The model was produced using PolyJet technology and includes full color as well as transparent and semi-transparent structures. What advantages do those capabilities offer when visualizing complex brain anatomy and tumors?

For optimal surgical planning, the brain parenchyma was segmented to serve as the overall structure of the model. In this case, that meant that the model would contain anatomical structures encapsulated within others, so printing the brain tissue in clear material allowed for better visualization.

Green was selected as the color for the tumor so it would stand out clearly as an abnormal structure. The optic, language and corticospinal tracts were printed in semi-transparent light green, orange and blue respectively. These pathways needed to remain visible without obstructing other important anatomy, as they were referenced by the surgeons to determine where incisions should be made during surgery.

Additional landmarks intersecting with the tumor were also segmented, including the sagittal sinus in dark blue, the brainstem in pink, the ventricles in cyan and the corpus callosum in yellow.

PolyJet technology allows multiple colors and varying levels of transparency to be printed within the same model, which significantly improves visualization of complex neuroanatomy. In this case, the transparent brain parenchyma allowed surgeons to see internal structures, while color-coded segmentation of the tumor, ventricles, brainstem, vasculature and functional tracts made it easier to distinguish critical anatomy and understand their spatial relationships.

Semi-transparent coloring of structures such as the optic, language and corticospinal tracts allows these pathways to remain visible without obscuring other anatomy. This combination of transparency and color helped surgeons better appreciate the tumor’s relationship to eloquent brain regions and plan a safer surgical trajectory.

3DN: You will be presenting in the Healthcare Showcase Knowledge Bar at RAPID + TCT, which is open to anyone with an Expo Pass. Why should attendees make time to visit this part of the event?

I would encourage anyone attending RAPID + TCT to visit the Healthcare Showcase to see models like this in person. Being able to hold a detailed anatomical model and examine it closely is a very different experience than simply viewing it on a screen.

I’m also excited about the opportunity to have one-on-one conversations in the Knowledge Bar with other professionals in the additive manufacturing industry. Being able to share and discuss my work with others who are equally passionate about additive manufacturing is very exciting.

I anticipate that many great conversations and new connections will come from this exhibit, and that attendees interested in the field will gain valuable knowledge from the Showcase. The fact that the showcase is healthcare-focused is also a great bonus, as I’ll get to see firsthand the many other ways 3D printing is being used to support the medical field.

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*Cover Photo Credit: Maggie Lashutka