These custom ballistic gel-based phantoms provide trainees with medium-fidelity median, femoral, suprainguinal fascia iliaca plane, and serratus anterior plane nerve block training for a fraction of the cost of commercially available nerve block phantoms (Table 1). Our first median and femoral nerve block trainers were made in-house for 12% and 9% of the price of the cheapest commercially available median and femoral nerve block trainers, respectively. None of the available femoral nerve block phantoms are capable of simulating the suprainguinal approach to the fascia iliaca block as our phantom does. We could find no commercially available serratus anterior plane ultrasound phantoms.
Table 1: Summary of commercially available ultrasound-guided regional anesthesia phantoms. Please click here to download this Table.
In the last decade, 3D printing technology has become more accessible and more affordable. For example, the Original Prusa i3 MK3S+ 3D printer used in this protocol, though not the latest edition, costs just $64919. Even the smaller Prusa MINI+, which is sufficient for making the models detailed herein, costs just $42920. Most replacement parts for these printers are 3D-printed themselves, further minimizing repair costs. Students and faculty can generally access 3D printers for free through their institution's makerspace or design lab. Designing objects to 3D print is more convenient than ever using computer-aided design (CAD) programs, some of which are available for free21.
The length of time required to design the 3D-printed models and simulated bones varies depending on the user's skill and familiarity with CAD software; however, this process can be done without cost using software such as FreeCAD or by utilizing CAD software licensed by the host institution21. Creating silicone molds of each tissue layer is not time-intensive. Silicone costs $28 per kg with each phantom requiring 4-6 kg of silicone ($140 total). Since the silicone molds are reusable, this is a one-time expense.
Our commercial ballistic gel costs $86 per kg, and each phantom required approximately 0.7 kg for a cost of $60 per phantom. 3D printing structures required for molding require negligible costs of PLA or ABS filament. Two of our phantoms required 100 mm of yarn at $10 per m or $0.01 per phantom. In total, each phantom cost ~$200 to make the first model and $60 to make each subsequent model. The production process required 1 man-hour and 3-4 h of gel heating and cooling. We have been able to build four models concurrently in the same timeframe.
Ballistic gel is an ideal medium due to its versatility. It can be used to simulate a variety of tissues and can be melted and molded into any shape. Once the gel is solidified, any imperfections or needle punctures are somewhat self-healing and can be further mended using a heat gun. If there is a mistake in the phantom, or if it becomes damaged or overused, the ballistic gel components can always be disassembled, cleaned, and melted back down to be reused with minimal material loss. Ballistic gel is also cost-effective. Despite being the most expensive component of these phantoms at $86 per kg, these phantoms are still far more affordable than commercially available ultrasound phantoms (Table 1). Phantoms made using homemade gelatin have been previously described and are presumably even more affordable, but these phantoms will develop mold within days to weeks, even when stored in a refrigerator16. We have stored the phantoms in a clean, dry environment at room temperature for months to years without spoiling or degradation.
Simulating nerves in gelatin for ultrasound-guided nerve block models has proven difficult for educators. Previous attempts have utilized animal tendons22,23,24, electrical wire25, wooden dowels25, shoelaces26, metal rods27, bundles of rubber bands15, foam28, peas29, spaghetti30, and even an Ethernet cable31. These options are unrealistic, perishable, or create significant posterior acoustic shadowing under ultrasound. We used a household item, yarn, to create high-fidelity simulated nerves with little-to-no posterior shadowing for just $0.10 per m, or $0.01 per phantom.
ABS filament was used for 3D printing of imitation bone due to its higher heat tolerance than PLA, which warped in subsequent steps during the development of this method. We maximized the bake temperature to minimize melt times and decrease viscosity and number of bubbles. This allows for smoother, more space-filling pours into the silicone molds while also maintaining the temperature below the burning temperature of the gel, thereby avoiding excess smoke production.
The primary drawback to these phantoms is the time and energy required to design and build them. Designing tissue planes using CAD requires technical skill, and 3D printing models of them requires a basic knowledge of 3D printers, slicing an STL file, choosing a filament, and which settings and temperatures to use. Creating silicone molds for each tissue plane adds expense, as silicone is the second-most expensive component of this protocol at $28 per kg. However, these silicone molds are durable and reusable, so once they are made, they can be reused to create numerous ultrasound phantoms. Other drawbacks include the learning curve associated with mixing and pouring ballistic gel, as well as the lack of technological integration of these phantoms when compared with high-fidelity commercial mannequins. That said, we consider the relative ease of construction, ease of material acquisition, customizability, low cost, and recyclability of this model design to far outweigh its drawbacks. We hope that the dissemination of their construction method will facilitate improved training of nerve block procedures in facilities that cannot afford frequent replacement of expensive commercial medical simulation devices. Future studies should explore custom phantoms for additional nerve block procedures and assess the satisfaction and clinical performance of trainees utilizing these phantoms compared to their peers.