All the methods described in this protocol were applied in our institute. A representative case is presented to demonstrate the straightforward application of the method. Figure 1 presents a case of an orbital floor fracture. Figure 1A,B show the displacement of the orbital floor in coronal and sagittal CT views, respectively. Notice the large displacement, both in the antero-posterior aspect and in the latero-lateral aspect. Lateral and medial ledges exist, and the posterior ledge is intact but located in a very posterior position.
CT was uploaded to the segmentation software (Figure 2 and Figure 3). Next, segmentation of the fractured orbit (Figure 4, Figure 5, Figure 6, and Figure 7) and floor (Figure 8 and 9) was performed, creating two STL files. The STL files were uploaded to a 3D design software (Supplementary Figure 1). Minor gaps were corrected, and a mesh was created (Supplementary Figure 2). The gap was not small enough for the use of automatic gap filling (Supplementary Figure 3). The fractured segment could not be repositioned to the correct position. Notice both edges of the segment were displaced, and thus, a rotation only function was not possible (Supplementary Figure 4). There was too much comminution; thus, there was a need for the mirroring technique (Supplementary Figure 5 and Supplementary Figure 6). The reconstructed segment was moved inferiorly to avoid over-projection of the final PSI into the orbital space (Supplementary Figure 7). It is important to remember that PSI thickness is larger than that of commercial prefabricated orbital titanium plates. A PSI was created with anchoring arms and draining holes (Supplementary Figure 8 and Supplementary Figure 9). The curvature of the anchoring arms will help find the single exact spatial position of the mesh intraoperatively. Any intraoperative rocking of the mesh means improper positioning or design errors. Also, remember to keep away from the infraorbital foramen in the design of the anchoring arms. The abundance of draining holes is a mandatory part of the design to prevent intraorbital edema/blood accumulation, posing a risk of developing orbital compartment syndrome.
Following a forced duction test, the surgical procedure included a midtarsal incision. A transconjunctival incision is also possible in these cases. Following a subperiosteal dissection, the orbital wall defect was exposed. Orbital content inferiorly displaced into the maxillary sinus was elevated and the PSI was placed in an unequivocal position based on the accurate anatomical match of the bony ledges and inferior orbital rim (anchoring arms). A forced duction test was performed again before closing the surgical cut, which exhibited no mechanical limitations to ocular movement. In addition, it is important to check for ocular proptosis following dissection and implant placement. The periosteum and skin were sutured. Post-op CT was performed.
Figure 1C,D show the reconstructed orbit using a PSI in coronal and sagittal CT views, respectively. Notice the use of the lateral and medial ledges for support to the PSI placement while avoiding the posterior ledge as it is very posteriorly positioned. Placement of the ledge over it may result in movement restrictions and changes to the orbital volume. Thus, the posterior end of the PSI was designed to lay in continuation with the ledge.

Figure 1: Pre- and post-operative imaging of a patient suffering from an orbital floor fracture. (A) Pre-op coronal CT view demonstrating the orbital floor fracture observed by a displaced fracture segment. (B) Sagittal view of the same patient demonstrating the inferiorly displaced fractured orbital floor. (C) Post-op coronal CT view of the same patient showing the reconstruction of the floor using a PSI. Notice the superior structure and position of the PSI. (D) Sagittal view of the same patient. Notice the anatomical reconstruction of the floor using the PSI showing the "lazy S" structure in the posterior region of the floor. Please click here to view a larger version of this figure.

Figure 2: Upload CT for segmentation. To insert the DICOM, press File > Add DICOM files button for importing and segmenting the 3D model. Please click here to view a larger version of this figure.

Figure 3: Choose the appropriate plane. Coronal multi-planar reformation (MPR) of the patient's CT is selected with a slice width of 1 mm. Click the Add button. Please click here to view a larger version of this figure.

Figure 4: Bone segmentation interface. The 3D model is observed on the left, and the coronal CT view on the right. Press the Bone segmentation icon on the toolbar and choose Thin bones option. The first step in the segmentation process is defining the New Mask (right upper corner of the screen). Note the slice width is 1.000 mm (Left upper corner of the screen). Please click here to view a larger version of this figure.

Figure 5: Defining region for segmentation. (A) Click on any area of the fractured bony orbit to start defining a New Mask (green area). (B) Each click adds an additional volume of a bony segment. (C) Keep selecting different areas until the full orbit is marked. This process can be performed on both the 3D view and the slice view. (D) Before proceeding to the next step, verify that all bony parts of the orbit are selected on the axial and sagittal views. Please click here to view a larger version of this figure.

Figure 6: Creating a mesh. Select the 3D button on the toolbar. A selected mask will be built into a model defined as Mesh. Please click here to view a larger version of this figure.

Figure 7: Inspecting and exporting the mesh. A 3D model (Mesh) of the orbit is presented on the left screen. Press File > Save as and under Format choose STL. An STL model of the orbit will be exported. Please click here to view a larger version of this figure.

Figure 8: Multi-slice interpolation segmentation method. In cases where the fractured segment of the floor is not comminuted (right coronal view), the Multi-slice interpolation is used to create a separate mesh for this segment. Please click here to view a larger version of this figure.

Figure 9: Create the fractured segment. Using the Multi-slice interpolation and then the Paint areas icon it is possible to select the fractured segment on the coronal view in several random different slices. Then, using the Interpolate function for the automatic selection of the fractured segment, the segmentation is performed. The floor segment can now be exported as an STL file. Please click here to view a larger version of this figure.
Supplementary Figure 1: Import STL to the 3D design software. Click on File > Import Model and select the STL file exported in Figure 7. Please click here to download this File.
Supplementary Figure 2: Turn Clay to Mesh. First, Full clay continuity of the perimeter around the defect is achieved, and then the transformation of Clay to Mesh is performed. (A) Small gaps around the fractured floor area (white arrow), (B) Manually connecting these areas to achieve full continuity of the fracture perimeter (black arrow). (C) Smoothing the added clay. (D) Creating the new Mesh. Please click here to download this File.
Supplementary Figure 3: Automatic gap filling. (A) Selecting the margins of the defects. (B) Deleting the margins. (C,D) Fill the holes until the floor is recreated completely (D). Please click here to download this File.
Supplementary Figure 4: Anatomic repositioning sequence. In case the fractured segment was displaced as one-piece, anatomical repositioning is the easiest and most accurate option. (A) The STLs of the orbit and that of the floor segment are imported (Supplementary Figure 1), and the floor piece is activated (right-click - Activate). (B) Under Select and Move Clay, the Reposition tool is chosen, and the Move only option is deselected. (C) The floor is manually repositioned to fit the anatomical intact borders. (D) Another method to reposition the fractured segment is possible in cases where one of the fragmented edges is positioned in the correct anatomical location. During this repositioning method, the center of rotation is fixed in space. Please click here to download this File.
Supplementary Figure 5: Mirroring technique. In cases of large and comminuted orbital defects, the mirroring technique will produce a more accurate result. (A) Right orbital floor lacking a large portion of the bone. The left intact orbit was segmented. (B) Using the Mirror clay tool, the plane position is oriented to the medial side (blue line). (C) Mirror Entire Piece and Preview are checked, then Apply. (D) New mirrored object of the left intact orbit. Please click here to download this File.
Supplementary Figure 6: Superimposition of the mirrored and fractured orbits. (A) Using the Register pieces tool the mirrored orbit is selected as the Source and fractured orbit as the Target. (B) Markers are placed on unique anatomic locations in the mirrored orbit and similar locations in the fractured orbit, then Apply is clicked to superimpose the segments. (C) Auto is selected for optimal superimposition. (D) Superimposed mirrored orbit serves as a guide for anatomical reconstruction of the fractured orbit. Please click here to download this File.
Supplementary Figure 7: Orbital floor preparation. The reconstructed floor is depressed by 0.8 mm on the vertical axis. This vertical distance will match the thickness of the designed titanium mesh, thus preventing the mesh from encroaching on the inside of the orbit and reducing its volume. (A) Under Select/Move Clay, Reposition Origin is selected, and then To Center. The triad is moved to the center of the mirrored orbit floor. Rotate Only is chosen, and the Z-axis is positioned vertically, the X-axis horizontally, and the Y-axis anteroposteriorly (B) Under Select/MoveClay, Reposition Piece is selected. Then, Show/Hide Advanced Settings and Translate Step are amended to 0.8 mm. Arrowheads in the red rectangle are clicked in order to sink the mirrored orbit into the fracture orbit until the intact borders of the fractured area just start to appear. (C) Another click on the downward arrowhead in the green rectangle is performed to sink the floor of the mirrored orbit another 0.8 mm. This depth will match the PSI thickness, thus recreating the original floor. (D) Under Select/Move Clay, Select Clay is selected, and the Lasso Select Tool is used. The anatomical perimeter of the floor is selected. Invert Selection is chosen, and then the rest is deleted. The borders of the floor are smoothed, or clay is added to fit the borders of the fractured orbit. Please click here to download this File.
Supplementary Figure 8: Design the PSI. (A) Orbit and floor objects are selected, right-clicked and Boolean/Combine as New is chosen to create a single object of the orbit, including the anatomically reduced and depressed floor. Borders are smoothed an additional time. (B) Final object is duplicated, right clicked, and See Through is chosen, followed by Turn On. (C) Draw Curve is selected under Curves, and an outline is created just around the original fractured area - the curve must rest on the edges of the fractured orbit. The curve can rest on the newly created floor only in missing areas of bone (e.g., lateral posterior edge in the example - black arrow). When fully outlined, the Fit to Clay on Create icon is clicked. (D) In the same way, the anchoring arms of the PSI are created. Please click here to download this File.
Supplementary Figure 9: Finalize the PSI. The mesh and anchoring arms are embossed and then connected. Fixation and draining holes are created. (A) Under Detail Clay, Emboss With Curve is selected and a distance of 0.8 mm is chosen. The inside of the outlined area is selected, and Raise is clicked. (B) Add Clay and Smooth are used to connect the anchoring arms to the main body of the implant (black arrows). (C) The Boolean and Remove From functions are applied to the duplicated object. (D) In the object list, Clay coarseness is right-clicked -0.1 mm is chosen. Under Sculpt Clay, the Carve tool is chosen, and Tool Size is set to 2.1 mm -fixation holes are created on the most distant part of the anchoring arms. Tool Size is set to 1.5 mm and 1 mm to create draining holes on the rest of the PSI - holes near the edges of the implant are avoided. A final Patient Specific Implant is presented. Boolean and Remove From are always used to subtract the original fractured orbit from the final PSI to ensure a passive seat of the implant on the bony edges of the fractured orbit. Please click here to download this File.