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Surge Mold
Surgeon reviewing the digital design of a facial prosthesis over the patient's CT scan

For surgeons and dentists

From scan to fit,with no middlemen.

You send the CT scan. We design, validate and produce the custom prosthesis for your case, with the rigor the operating room demands.

Indications

What we make to measure

Every prosthesis is designed on your patient's anatomy. If the case calls for its own geometry, it belongs here.

Specialist pointing at the midface implant on the 3D model

Reconstruction

Bone loss from trauma, tumor resection or malformation, restoring volume and contour.

Skull model with printed midface prostheses

Facial contour

Mandible, chin and zygoma onlays for harmonization, designed on the real anatomy.

Mandible model with a chin prosthesis

Precision fit

Prostheses that seat on a specific bone bed, with the fit verified before production.

How to submit a case

Four steps, no bureaucracy.

You follow the case from submission to delivery, and approve the design before any physical production.

What you need to send

  • CT scan in DICOM, slices up to 1 mm
  • Intraoral scan or STL, when available
  • Surgical goal and the region to be treated
  • Planned surgery date, if already set
  1. 01

    Case submission

    You send the scans and the surgical goal. We come back with feasibility.

  2. 02

    Digital design

    We model the prosthesis on the anatomy segmented from the CT scan.

  3. 03

    Your approval

    You review the design and request changes. Nothing is produced without your sign-off.

  4. 04

    Production and delivery

    Printing by Compass 3D, dimensional control and sterilizable shipping.

Material

Medical-grade PMMA.

Polymethyl methacrylate, the same material established in cranioplasty. Stable, biocompatible and machinable in the operating room when the case calls for a fine adjustment.

Biocompatible

Established use in cranial and facial implants.

Radiolucent

Creates no artifact in follow-up imaging.

Stable

Holds shape and volume over time.

Adjustable

Accepts grinding and drilling intraoperatively.

3D render of the facial mesh

Technology and control

What guarantees the prosthesis fits.

The whole path is digital and traceable. What you approved is exactly what gets produced.

  1. 01

    CT segmentation

    Bone is reconstructed in 3D from the DICOM, preserving the real geometry.

  2. 02

    Geometric validation

    Digital overlay between prosthesis and bone bed before releasing production.

  3. 03

    Precision printing

    Additive manufacturing by Compass 3D, with parameters controlled per batch.

  4. 04

    Dimensional check

    The printed prosthesis is compared against the approved design before shipping.

Produced in partnership withCompass 3DRegulatory complianceCertified facility

Frequently asked questions

What surgeons usually ask

How long does it take from submission to delivery?

The timeline depends on the complexity of the case. Once we receive the scans, we come back with a firm timeline alongside the feasibility analysis. Cases with a scheduled surgery date enter a priority flow.

Can I request changes to the design before production?

Yes. The digital design is sent for your review and nothing is produced without your approval. Contour, thickness and support area adjustments happen at this stage, while there is still no material cost.

Does the prosthesis arrive sterilized?

The prosthesis is delivered clean and ready for your institution's sterilization protocol, along with handling instructions. Final sterilization follows the operating room's routine.

Can the prosthesis be adjusted during surgery?

Yes. PMMA accepts grinding and drilling intraoperatively, which lets you refine the seating or create fixation points without compromising the prosthesis.

Which scan do you need to receive?

A CT scan in DICOM files, preferably with slices up to 1 mm. Intraoral scans or STL files are welcome when the case involves a relationship with the teeth.

Do you serve the whole country?

Yes. The entire analysis and design path is digital, and the prosthesis is shipped to the clinic or hospital address you provide.

Have a case in hand? Let's look at it together.

Send the CT scan and the surgical goal. We come back with the feasibility and timeline for your case.