Toward surface-based registration of a virtual preoperative cutting guide onto the mandible for reconstruction surgery

Positive margins in head and neck oncologic surgery require mapping specimen-side pathology findings to the patient resection bed. This is challenging because pathologists identify the positive margin on slices of the resected, deformed specimen, while surgeons must relocate the corresponding site on the resection bed using only verbal descriptions and no visual guidance. We present a marker-free augmented reality (AR) workflow for mapping a margin label from a three-dimensional specimen scan to the resection bed. The method combines contour-constrained deformation, residual alignment to a depth scan, surface-based fusion to a head-mounted display, and target projection onto the reconstructed bed. Bead-suture correspondences estimate specimen deformation, whereas patient-to-display fusion does not require external fiducial markers. Following formative experiments, five residents and surgeons performed cadaveric cheek and scalp re-resection tasks under verbal guidance, verbal guidance with specimen examination, and AR guidance. Deformation target errors were $7.63 \pm 3.74$ mm for the cheek and $3.72 \pm 1.02$ mm for the scalp; residual specimen-to-bed distances were $2.43 \pm 2.15$ mm and $2.19 \pm 1.06$ mm, respectively. Fusion error did not differ significantly between marker-free and marker-based methods on either cadaver; overall marker-free fusion error was $2.15 \pm 0.87$ mm. End-to-end margin localization error decreased from $21.40 \pm 3.84$ mm with verbal guidance and $16.09 \pm 4.30$ mm with specimen examination to $6.19 \pm 1.79$ mm with AR guidance ($p < 0.001$). Online fusion required $5.23 \pm 0.34$ s. These results demonstrate effective marker-free AR guidance for positive-margin localization and support more precise tumor resection.

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.

Registration between cone-beam computed tomography (CBCT) and intraoral scans (IOS) is essential for patient-specific surgical planning. However, disparate imaging modalities, limited overlap, and large pose offsets make automated registration unreliable. Consequently, clinical registration remains dependent on conventional geometry pipelines and manual clinician adjustment. To address these challenges, we propose APCReg, an anatomical-prior-guided coarse-to-fine framework for global registration and reliability-controlled residual correction. Specifically, multi-view anatomical coarse registration (MACR) performs ordered orthogonal projection alignment (buccal, proximal, and occlusal) to decompose the six-degree-of-freedom search before three-dimensional refinement. Overlap-aware residual registration (OARR) combines shared KPConv features, a folded arch-length cue, overlap-gated cross-attention, and Sinkhorn matching. Finally, dental-arch-structured hypothesis selection evaluates diverse poses on held-out reliable correspondences, while a ground-truth-free coarse-retention guard conditionally retains a geometrically reliable coarse pose. On 60 held-out jaw pairs, APCReg achieves a submillimeter mean Chamfer distance of 0.87 mm and a Hausdorff distance of 2.92 mm under this evaluation protocol, and ranks first across the six reported metrics among the evaluated open-source baselines.