Mayo Clinic researchers have developed and tested a new 3D surface scanning approach that gives neurosurgeons even greater precision when operating deep inside the brain.
The system aligns a patient's head, facial features and surgical head frame with brain images, achieving sub-millimeter accuracy - a level of precision that can make a critical difference in delicate procedures.
In a feasibility study published in the Journal of Neurosurgery, the 3D scanning method proved more accurate than the CT scan typically used during neurosurgery, all while eliminating exposure to radiation.
Researchers say the approach could make complex procedures, such as deep brain stimulation, drainage and biopsies safer and more efficient, while enhancing patient comfort. Because it integrates with most surgical navigation systems, it may also bring high-precision guidance to operating rooms that don't have a CT scanner.
How the new 3D approach works
Using cameras and structured-light scanning, the new system creates high-resolution 3D models of the patient's face and the surgical frame that keeps the head still. It merges these images into a detailed spatial "map" of the patient's position in the operating room. That map is then matched with pre-surgery brain scans, such as MRI or CT images, giving surgeons precise, real-time guidance to reach the exact target in the brain.
In the study, the system's computer analysis aligned images with an average precision of 0.14 millimeters - compared with about 0.20 millimeters typically achieved with CT scans. The difference is roughly the width of a pencil tip, but in delicate brain surgery, that fraction can be enough to affect accuracy.
Teamwork behind the breakthrough
The project combined Mayo Clinic's engineering and surgical expertise. Jaeyun Sung, Ph.D., a Mayo Clinic computational biologist, clinical AI researcher and corresponding author, led the engineering and computational work. Dr. Sung focuses on using engineering and computer science to develop advanced precision medicine tools for patient care.
"When engineers and neurosurgeons look at the same challenge, we see different details, and that's where breakthroughs can happen," Dr. Sung says. "This is about building the next generation of surgical tools that bring engineering-level, sub-millimeter precision directly into the operating room."
Kendall Lee, M.D., Ph.D., a Mayo Clinic neurosurgeon, led the surgical integration of the technology and said it could make a real difference for patients and improve his practice.
"Some of the most important steps in neurosurgery happen before we even begin the operation," Dr. Lee says. "This new 3D scanning method is safe, quick and cost-effective, and it can help us hit the right target more accurately, improving how we care for patients."
Basel Sharaf, M.D., D.D.S., a Mayo Clinic surgeon and lead author of the study, sees even greater possibilities ahead for the technology.
"In the future, 3D surface scanning could be as simple as using a smartphone," Dr. Sharaf says. "With advanced AI, the system could adapt in real time, even predicting small shifts in the brain to help surgeons work with greater accuracy and a smoother workflow."
Next Steps: Advancing automation, AI and clinical validation
The team is now working to add automation and artificial intelligence to help make the process faster and easier to use. They are also testing new hardware and running a larger clinical trial to further evaluate the technique's effectiveness in brain surgery.
Review the study for a complete list of authors, disclosures and funding.
