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In each post, I highlight a specific application, whether it’s a part printed here at AdvancedTek or one featured in customer stories from our partners, and walk through the decisions behind the print and what actually mattered to make the part successful in the real world. This isn’t about perfect lab conditions or theoretical designs; it’s about practical additive manufacturing and lessons you can apply directly to your own parts. --- ## **The Part at a Glance** Part(s): Surgical Cutting Guides Industry: Medical Printer: [Formlabs Fuse 1+ 30W](https://advancedtek.com/3d-printers/formlabs-fuse-1-30w/) Material: Nylon 12 Primary Requirements: Accurate fit, reliable performance ![Surgical Guide 1_SLS_Fuse 1+30w](https://6976905.fs1.hubspotusercontent-na2.net/hub/6976905/hubfs/Surgical%20Guide%202_wht_Bckgnd.v2.crop-1.png?width=1200&length=1200&name=Surgical%20Guide%202_wht_Bckgnd.v2.crop-1.png) ![Surgical guide 2_SLS_Fuse 1+30w](https://6976905.fs1.hubspotusercontent-na2.net/hub/6976905/hubfs/Surgical%20guide%201%20Wht_Bckgrnd.v2.crop-2.png?width=1200&length=1200&name=Surgical%20guide%201%20Wht_Bckgrnd.v2.crop-2.png) ![Surgical Guide 3_SLS_Fuse 1+30w](https://6976905.fs1.hubspotusercontent-na2.net/hub/6976905/hubfs/Surgical%20Guide%203_Wht_Bckgrnd.v2.crop-1.png?width=1200&length=1200&name=Surgical%20Guide%203_Wht_Bckgrnd.v2.crop-1.png) ![Surgical Guide 4_SLS_Fuse 1+30w](https://6976905.fs1.hubspotusercontent-na2.net/hub/6976905/hubfs/Surgical%20Guide%204_Wht_Bckgrnd.v2.crop-1.png?width=1200&length=1200&name=Surgical%20Guide%204_Wht_Bckgrnd.v2.crop-1.png) ![Surgical Guide 5_SLS_Fuse 1+30w](https://6976905.fs1.hubspotusercontent-na2.net/hub/6976905/hubfs/Surgical%20Guide%205_Wht_Backgrnd.v2.crop-1.png?width=1200&length=1200&name=Surgical%20Guide%205_Wht_Backgrnd.v2.crop-1.png) ## The Why's: ### Why Additive? For this project, we were working on custom surgical cutting guides; basically, patient-specific tools that help surgeons make extremely precise bone cuts during procedures like fracture repair or [osteotomies](https://formlabs.com/blog/sls-3d-printed-surgical-guides-anatomical-models-fracture-treatment-osteotomy/?srsltid=AfmBOop0ze5Mg75POe0anPXBpSixSAGKeFGIX548HK5ZHZlCJKYc3v5v) (bone realignment surgeries). The part files were provided by Formlabs and printed in our [St. Paul TekCenter](https://advancedtek.com/why-advancedtek/tekcenter-3d-printer-demo/) to be used as display parts for an upcoming medical-focused trade show. The goal of surgical guides is simple: take a digital surgical plan and turn it into something physical that makes the surgery faster, safer for the patient, and more accurate. Before guides like this became more common, surgeons often had to rely on standardized tools and a lot of real-time measuring in the OR. That works, but it can be time-consuming and leaves more room for variability and mistakes during the procedure. With all cutting guides, the following are non-negotiable: •    The guide must fit well with the patient’s anatomy •    The part needs to be sterilizable •    The cut slots and drill paths need to be dimensionally accurate •    The workflow needs to be fast enough for point-of-care use This is an application where additive manufacturing shines. Every patient is different, so every guide should be uniquely tailored; something that would make traditional manufacturing cumbersome and inefficient. With 3D printing, you can have unlimited variability while achieving fast, precise, and repeatable results. ### Why the Formlabs Fuse? ### ![](https://info.advancedtek.com/hs-fs/hubfs/Optimized_For_Web_PNG-Formlabs_FUSE%201+%2030W%20Printer_36.png?width=400&height=267&name=Optimized_For_Web_PNG-Formlabs_FUSE%201+%2030W%20Printer_36.png) I felt the [Formlabs Fuse 1+ 30w](https://advancedtek.com/3d-printers/formlabs-fuse-1-30w/) would be a great match for this build because SLS printing gives you:  •    Functional, durable nylon parts •    The ability to print complex shapes without supports •    Consistency across builds •    The option to batch multiple guides at once For hospitals or medical centers building these at the point of care, the combination of speed, accuracy, and in-house cost efficiency is unparalleled.     ### Why Nylon 12? Nylon 12 was chosen because it strikes a balance between strength and accuracy, plus is sterilizable. It’s a practical material choice when you need performance, not just a prototype. ## The Nitty Gritty ### Support Strategy:  The best part about the Formlabs Fuse and SLS in general, is the lack of supports needed.  This ensures the contact surfaces are clean and scar free, which is imperative when the perfect fit matters!  ### Key Settings and Considerations:  - Tight tolerances around cut slots and drill holes - Nesting multiple guides (parts) into one build to maximize throughput ### The Tradeoffs:  The main tradeoff here is surface finish vs. speed. Because SLS is a powder-based process, parts can have a slightly textured feel so, depending on the surgeons requirements, some guides may need light post-processing e.g., smoothing, polishing. Even with this step, SLS remains significantly faster and more flexible and traditional manufacturing methods.  ### Notable Outcomes: - Faster turnaround times (3 days for printing and post-processing) compared to outsourcing surgical guides using traditional manufacturing methods. - Cost Savings. Having direct access to additive can minimize external manufacturing disruptions, and reduce costly procedure time in the O.R. - Patient-precise geometry that's difficult to achieve using traditional manufacturing methods.  ## Lauryn's Pro Tip If you’re planning to print surgical cutting guides, always treat the bone‑contact surface as the critical surface. The guide is only as accurate as its fit, and SLS is especially valuable here because you can produce complex geometry without supports interfering with those contact surfaces. Every part tells a story, and this is a great example of how additive manufacturing can simplify workflows, speed up timelines, and unlock designs that aren’t practical with traditional methods. If you’re working on a part and wondering whether additive manufacturing could be a good fit, or which technology or material makes the most sense, our Application Engineers are always happy to talk through it. --- #### Share: - [Follow us on Facebook](http://www.facebook.com/share.php?u=https://info.advancedtek.com/blog/whats-printing-with-lauryn-surgical-cutting-guides) - [Follow us on Linkedin](http://www.linkedin.com/shareArticle?mini=true&url=https://info.advancedtek.com/blog/whats-printing-with-lauryn-surgical-cutting-guides) - [Follow us on Mail](mailto:?subject=Whats%20Printing%20with%20Lauryn:%20Surgical%20Cutting%20Guides%20&%20body=https://info.advancedtek.com/blog/whats-printing-with-lauryn-surgical-cutting-guides) --- #### [AdvancedTek Adds Formlabs 3D Printers to Its Portfolio, Enhancing Access to Professional SLA & SLS Additive Manufacturing Solutions Across the Midwest Previous Post](https://info.advancedtek.com/blog/advancedtek-adds-formlabs-3d-printers-to-its-portfolio-enhancing-access-to-professional-sla-sls-additive-manufacturing-solutions-across-the-midwest) #### [In-House 3D Printing vs. Outsourcing: What Midwest Manufacturers Need to Know Next Post](https://info.advancedtek.com/blog/in-house-3d-printing-vs.-outsourcing-a-cost-and-lead-time-analysis-for-midwest-manufacturers) ### Popular Posts 01/25/2023 [Ask a 3D Printing Expert: Can Stratasys F123 Series build trays be reused?](https://info.advancedtek.com/blog/ask-a-3d-printing-expert-can-f123-series-build-trays-be-reused) 03/15/2023 [Ask a 3D Printing Expert: What Stratasys materials are most similar to PTFE, Polypropylene, and Delrin?](https://info.advancedtek.com/blog/ask-a-3d-printing-expert-what-stratasys-materials-are-most-similar-to-ptfe-polypropylene-and-delrin) 04/08/2025 [AdvancedTek Adds Formlabs 3D Printers to Its Portfolio, Enhancing Access to Professional SLA & SLS Additive Manufacturing Solutions Across the Midwest](https://info.advancedtek.com/blog/advancedtek-adds-formlabs-3d-printers-to-its-portfolio-enhancing-access-to-professional-sla-sls-additive-manufacturing-solutions-across-the-midwest) 08/15/2022 [FDM 3D Printing Technology: Then and Now](https://info.advancedtek.com/blog/fdm-3d-printing-technology-then-and-now) --- ## Stay Connected! 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All Rights Reserved. - [Privacy Policy](https://advancedtek.com/privacy-policy/) - [Sitemap](https://advancedtek.com/sitemap/) ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "Lauryn Ahlm", "url" : "https://info.advancedtek.com/blog/author/lauryn-ahlm" }, "dateModified" : "2026-05-15T13:46:19.250Z", "datePublished" : "2026-02-02T15:47:44.000Z", "headline" : "What's Printing with Lauryn: Surgical Cutting Guides", "mainEntityOfPage" : { "@id" : "https://info.advancedtek.com/blog/whats-printing-with-lauryn-surgical-cutting-guides", "@type" : "WebPage" }, "publisher" : { "@type" : "Organization", "logo" : { "@type" : "ImageObject", "url" : "https://info.advancedtek.com/hubfs/AdvancedTek_Logo_2%20Tone_RGB.png" }, "name" : "AdvancedTek" } } ``` ```json { "@context" : "https://schema.org", "@type" : "FAQPage", "mainEntity" : [ { "@type" : "Question", "acceptedAnswer" : { "@type" : "Answer", "text" : "A surgical cutting guide is a patient-specific tool used during surgical procedures to direct the precise placement of cuts, holes, or implants. Surgical cutting guides are designed from patient imaging data — typically CT or MRI scans — and are manufactured to match the exact anatomy of the individual patient. They allow surgeons to perform complex bone cuts and implant placements with greater accuracy and speed than freehand technique, reducing procedure time and improving consistency of outcomes." }, "name" : "What is a surgical cutting guide and how is it used in medical procedures?" }, { "@type" : "Question", "acceptedAnswer" : { "@type" : "Answer", "text" : "SLS (Selective Laser Sintering) 3D printing is well suited for surgical cutting guides because it produces strong, accurate, support-free parts from Nylon 12 — a material with established use in medical device applications. SLS does not require support structures during printing, which allows complex guide geometries to be produced without post-processing artifacts from support removal. The Formlabs Fuse 1+ 30W delivers the dimensional accuracy and surface quality required for patient-specific fit in surgical applications." }, "name" : "Why is SLS 3D printing used for surgical cutting guides?" }, { "@type" : "Question", "acceptedAnswer" : { "@type" : "Answer", "text" : "Nylon 12 (PA 12) is the material used for the surgical cutting guides featured in this application. Nylon 12 is a widely used SLS material with good mechanical properties, chemical resistance, and a well-established track record in medical device and surgical guide applications. For this application, the Formlabs Fuse 1+ 30W SLS system was used to produce the guides in Nylon 12." }, "name" : "What material is used to 3D print surgical cutting guides?" }, { "@type" : "Question", "acceptedAnswer" : { "@type" : "Answer", "text" : "The two primary requirements for surgical cutting guides are accurate fit and reliable performance. Accurate fit means the guide must conform precisely to the patient's anatomy as derived from imaging data, which requires a 3D printing process with consistent dimensional accuracy. Reliable performance means the guide must maintain its structural integrity throughout the surgical procedure without deformation or failure. SLS printing in Nylon 12 on the Formlabs Fuse 1+ 30W addresses both requirements." }, "name" : "What are the key requirements for 3D printing surgical cutting guides?" }, { "@type" : "Question", "acceptedAnswer" : { "@type" : "Answer", "text" : "The Formlabs Fuse 1+ 30W is an SLS 3D printing system capable of producing parts in Nylon 12 for medical device applications including surgical guides. Formlabs provides validated workflows and documentation to support medical applications of their SLS systems and materials. Organizations using 3D printed surgical guides for patient care are responsible for ensuring appropriate regulatory compliance for their specific application and jurisdiction. AdvancedTek's application engineers can discuss Formlabs' medical application resources in detail." }, "name" : "Can the Formlabs Fuse 1+ 30W be used for medical device applications?" }, { "@type" : "Question", "acceptedAnswer" : { "@type" : "Answer", "text" : "Yes. AdvancedTek serves medical device manufacturers across the Midwest, including Minnesota — one of the nation's largest medical device manufacturing hubs. Our application engineers can evaluate your specific application requirements, provide test prints in Nylon 12 on the Formlabs Fuse 1+ 30W at our TekCenter in St. Paul, Minnesota, and connect you with Formlabs' medical application resources. Contact AdvancedTek at advancedtek.com/contact-us or call 800-482-9005 to start the conversation." }, "name" : "Does AdvancedTek support medical device manufacturers interested in 3D printing surgical guides?" } ] } ```