Comparison between Custom 3D-Printed Titanium Meshes and Stock Titanium Meshes in Orbital Floor Repair: A Retrospective Analysis

Purpose: To compare the clinical outcomes of patient-specific customized 3D-printed titanium meshes (PSIs) and stock titanium meshes in orbital floor reconstruction. Methods: This retrospective case series included 48 patients undergoing orbital floor repair between June 2024 and March 2025. Patients were divided into Group 1 ( n = 22) receiving custom 3D-printed titanium meshes and Group 2 ( n = 26) receiving stock titanium meshes. Operative time, orbital volume restoration (via 3D volumetric analysis), resolution of enophthalmos, diplopia, and infraorbital paresthesia were assessed. Volumetric measurements were performed using semi-automatic segmentation based on CT scans. Results: The 3D-printed meshes achieved a better restoration of orbital volume, with a mean reduction in volumetric discrepancy of 89% (SD ± 28%), compared to 51% (SD ± 35%) in the standard mesh group ( P = 0.036). No statistically significant differences were observed in operative time or in the resolution of paresthesia. However, a statistically significant difference between the two groups was found in the resolution of both enophthalmos and diplopia ( P = 0.025 and P = 0.028). Conclusion: Custom 3D-printed titanium meshes showed improved anatomical accuracy and volumetric outcomes compared to stock meshes. Further prospective studies with long-term follow-up are necessary to confirm these findings and assess cost-effectiveness.