Export 3D Model for Printing

OsiriX and Horos Course · Image and Export

In this step-by-step tutorial I show how to turn a study (DICOM) into a 3D model that can be exported for 3D printing, using OsiriX. Open the study and generate the 3D reconstruction (Volume Rendering) Open the skull dataset. Adjust the preset to highlight bone (e.g., Bone/Standard) until the skull is clearly visible. “Clean up” the volume (remove tissues that are not of interest) Use the Scissors tool to erase soft tissue and unwanted structures. Optional: use the automatic bone removal tool, but here the method is manual. Adjust/trim artifacts (e.g., spicules from the prosthesis) to reduce imperfections. Confirm that the cut affected the dataset Exit the 3D window and check that the axial slices now have those regions removed (this ensures the “sculpted dataset” is ready). Generate the vector model (3D Surface Rendering) Open 3D Surface Rendering. For printing, use 1 surface (single surface) and set a threshold suitable for bone. Generate the surface model of the skull. Export to printing/editing formats Export as: STL (most common for 3D printers) OBJ (very useful for editing/alternative workflows) Important note: STL almost always needs processing before printing (closing holes, removing noise, fixing the mesh, etc.). Open in 3D editing software Import the STL/OBJ into an editor (e.g., Meshmixer, Blender, 3D Builder, etc.). From there you can: Fix artifacts and “spicules” Close holes Smooth the mesh Reduce the polygon count Prepare for slicing (slicer)