Marker-free deformable registration and fusion for augmented reality-guided positive margin localization during tumor resection surgery

With 890,000 annual new cases globally, head and neck squamous cell carcinoma has one of the highest recurrence rates among solid malignancies. Although frozen section analysis is the standard of care for intraoperative margin assessment, accurately relocating detected positive margins on the resection bed remains challenging due to imprecise alignment between resected specimens and their resection bed, compounded by post-resection mucosal tissue shrinkage. We present a biomechanics-driven deformable registration framework that corrects post-resection tissue deformation to provide intraoperative guidance. Our approach registers 3D specimen meshes to intraoperative resection bed point clouds using a deformable registration approach based on regularized Kelvinlet basis functions. The registration matches surface point clouds, fiducial landmarks, and boundary contour constraints that directly penalize perpendicular distance-to-agreement between specimen and resection bed boundaries. Across nine specimens from skin, buccal mucosa, and tongue sites, the overall mean target registration error was $11.11 \pm 4.07$ mm using rigid registration, which decreased to $8.20 \pm 2.68$ mm (26.19% reduction) using deformable registration without contour constraint. The proposed contour-constrained deformable registration further reduced the error to $5.62 \pm 2.28$ mm, a 49.41% reduction relative to rigid registration. We observed the largest reduction in the most clinically challenging tongue specimens. We also performed a systematic two-stage parameter search to characterize the relative importance of surface alignment, fiducial correspondences, contour constraint, and strain energy regularization. This search revealed that contour weighting dominates registration accuracy for tissue types with large lateral deformation, while the algorithm operates over a broad range of parameter combinations.

Mandibular reconstruction restores facial continuity and oral function after segmental resection. Patient-specific cutting guides transfer a computed tomography (CT)-based plan to the operating room with three-dimensional information, but printed guides add cost and lead time, cannot adapt after fabrication, and may interrupt surgery if sterility is lost. We investigate a markerless augmented reality (AR) alternative that registers a virtual cutting guide to the exposed mandible from surface geometry. The method extends surface-based registration for the transoral setting, where teeth form the most distinctive visible surface. After camera calibration, a HoloLens 2 time-of-flight camera captures a partial intraoperative point cloud. The user supplies a rough head-based alignment only to crop the region of interest. A teeth-weighted global stage computes correspondences and solves a truncated least-squares rigid alignment. An asymmetric point-to-plane iterative closest point (ICP) stage refines the complete CT mandible against the partial depth cloud target. The guide-to-mandible transform places the guide in the HoloLens world frame, while pose updates and interpolation follow target motion. We define a blinded phantom protocol with 30 target registration error (TRE) points under full, intermediate, and teeth-only exposure, plus a motion-to-display latency test. Our median TRE is 4.05, 6.10, and 7.10 mm respectively, and median latency is 0.805 s. These values support the feasibility of using AR to replace physical prints. The workflow removes mounted fiducials and manual landmark selection and provides a testable path toward transoral cutting guidance.

The handling and assembly of instruments during surgery imposes high cognitive demands on scrub nurses, particularly when instruments are unfamiliar. We present a supporting guidance system for surgical instrumentation that combines multi-camera 6D pose estimation with augmented reality in-situ visualization on a head-mounted display without the requirement for additional markers. Pose estimation and consecutive camera calibration are achieved through known objects. The 6D pose estimation network is trained purely on synthetic data, aiming for better generalizability and real-world applicability. The AR guidance displays tooltip localization cues and step-wise assembly animations. Via gaze-based selection and a foot pedal, users can switch between assembly steps in intraoperative use. In a technical evaluation, our approach outperforms state-of-art 6D pose estimation. A user study with 29 scrub nurses was conducted in a surgical simulation of knee arthroplasty, comparing the system against a paper manual. AR guidance significantly reduced the perceived workload compared. Objectively, AR guidance reduced task completion time by 21.3% (4.76 minutes). Specifically, scrub nurses less experienced with the instrument set benefited when using the system. Error frequencies were comparable between conditions. Qualitative feedback highlighted improved process clarity, reduced information overload, and perceived independence. To summarize, our marker-free multi-camera AR guidance approach for surgical instruments can, subjectively and objectively, improve intraoperative instrumentation performance, particularly for untrained scrub nurses.