When a child suffers a serious burn injury, the impact extends far beyond the initial trauma. Shriners Children’s burn specialists use advanced technologies and innovative treatments to improve healing, minimize scarring, restore function and help children achieve better long-term outcomes in both appearance and quality of life.
At Shriners Children’s Texas, a newly updated in-house 3D printer is playing a critical role in minimizing scarring for children recovering from facial burns. Access to this technology allows the burn rehabilitation team to deliver treatment more quickly and improve outcomes.
One of the most important tools in facial burn recovery is the transparent facial orthosis (TFO), a clear, custom-fitted mask that applies gentle, consistent pressure to healing skin, helping scars flatten and mature properly.
In the early stages of healing, scars can quickly become tight and raised. In the past, facial molds were outsourced, which often took weeks. Now, the 3D printer enables clinicians to begin treatment much sooner.
Physical therapist Chris Whitehead holds the 3D-printed mold used to create a custom-fitted facial mask for Tikva, 9, an important tool in burn recovery.
“If scars tighten too much, they can interfere with how the face moves and works. Applying proper pressure early is incredibly important,” said physical therapist Chris Whitehead, PT, at Shriners Children’s Texas.
A quick, noninvasive 3D scan of the child’s face is fine-tuned on a computer, then sent to the 3D printer to produce a physical mold. The mold is then used to shape a clear thermoplastic mask.
Because the masks are transparent, therapists can clearly see the scarring underneath and assess how well pressure is being applied. Scar rating scales help track progress over time, allowing care plans to be adjusted as healing progresses.
Patients typically wear their TFOs throughout scar maturation, which may last one to two years. As swelling decreases, scars soften or children grow, masks often require modification or replacement. Producing TFOs in-house allows our team to respond more quickly and collaborate closely, reflecting our commitment to patient-centered care and innovation.
Scar management techniques restore mobility and build confidence
Kim was at a lake near her home in Vermont when she received the kind of call every parent fears: Her two-year-old daughter Harper had been taken to a local hospital after falling into a fire pit. When Kim arrived at the hospital, she was told Harper’s injuries were severe and she would need to be airlifted to Shriners Children’s Boston for specialized burn care.
As Harper has grown, her care has transitioned to the scar-management phase, under the care of plastic surgeon Daniel Driscoll, M.D., who performed a z-plasty procedure on her thumb. This is a technique used to soften the appearance of a scar and improve the function of that part of the body by cutting into the scar with an incision that looks like the letter Z.
“A z-plasty is a way to treat a burn scar that has contracted and inhibits function. It borrows tissue from one direction to lengthen in another direction,” said Dr. Driscoll.
He also employs ultra pulse laser therapy on Harper’s scars about twice a year. Laser therapy is a less invasive approach to scar management compared to a traditional surgical procedure.
“Scars tend to get tighter as a child grows, so there is a need for long-term yearly follow-up. As Harper grows, we will see if she needs interventions such as lasers to soften the scars, z-plasty or grafts to treat functional contractures. It is a process that levels out after growth phases slow down,” Dr. Driscoll said.
Now, almost seven years after her burn injury, Harper is an active 9-year-old who loves sports. “She plays basketball, softball, soccer and she wrestles. I call her my ‘honey badger,’” Kim said. When she’s not playing sports, Harper loves to swim and play outside, ride bikes and fish.
Through compassion and leading-edge technology, Shriners Children’s helps young patients heal more fully and move forward with confidence.
