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India (English)
Case Study

Advancing Surgical Training with 3D Printed Anatomical Models

Discover how COSA is advancing surgical simulation with Stratasys Digital Anatomy™ technology


Developing 3D-Printed Human Skin Presets for Surgical Simulation

The complete report to review the experimental methodology, quantitative results, and benchmarking approach. The validated skin presets support a transition from variable, resource-intensive cadaver models to a scalable, reproducible digital-to-physical workflow.

By creating high-fidelity, multi-material anatomical models that replicate the look, feel, and behavior of human tissue, COSA is helping surgeons train more consistently, accelerate medical innovation, and reduce reliance on cadaver-based training.

Customer Profile

COSA Ltd. specializes in advanced 3D printing solutions for healthcare, creating high-fidelity anatomical models, surgical training tools, and medical device prototypes. Their bespoke solutions help surgeons and medical technology companies improve training, support innovation, and accelerate the development of new healthcare technologies.

3D printing allows us to do what cadavers cannot. We can control anatomy, introduce pathology, and create a truly scalable training platform."

Stratasys 3D printed surgical training eye

Challenge

COSA set out to overcome the limitations of cadaver-based surgical training. While cadavers provide anatomical realism, they vary from specimen to specimen, cannot reproduce specific pathologies on demand, and are costly and difficult to access. For complex procedures involving the temporal bone, surgeons also rely on subtle tactile and visual cues that traditional training models cannot accurately replicate. COSA needed a solution capable of delivering realistic anatomy with consistent mechanical behavior for repeatable surgical simulation.

Post production of a 3D printed Stratasys PolyJet surgical model

Solution

Using Stratasys Digital Anatomy technology and PolyJet™ multi-material printing, COSA developed anatomically accurate temporal bone models that replicate both the structure and biomechanical behavior of human tissue. By combining multiple materials within a single print, the models reproduce realistic drilling resistance, tissue transitions, and visual anatomical landmarks, providing surgeons with a highly realistic training experience while supporting customized anatomies and pathologies.

Impact

Using 3D printing to create realistic temporal bone models, COSA was able to create a scalable alternative to traditional cadaver-based training that improves surgical education and supports medical innovation.

Key benefits include:

  • Simulation of complex procedures – The same anatomy can be reproduced consistently, allowing multiple surgeons to practice identical procedures.
  • Innovation beyond training – COSA's models support preclinical device validation, human factors studies, and product development.
  • Scalable, high-fidelity simulation – Printing one specific anatomical region is more cost efficient and also supports scalable training programs.

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