Dave Richards, a 75-year-old cyclist from Devon, has been fitted with a 3D-printed prosthetic face after suffering severe burns in a crash caused by a drunk driver. The incident, which occurred in July 2021, left him with full-thickness burns to his head, as well as injuries to his back, pelvis, and ribs.
Richards was cycling with friends when a speeding drunk driver, who was on his phone, struck the group. While his friends were thrown clear, Richards became trapped under the vehicle. “I was rolled along, with the engine and exhaust burning through one side of my body and the other side being crushed by the car,” he said.
Surgeons initially attempted to save his eye but were forced to remove it due to infection risk. He underwent a free flap procedure, where tissue with blood vessels was taken from elsewhere in his body and attached to his neck to cover the side of his face. He was later referred to the Bristol 3D medical centre, the first NHS facility in the UK to offer 3D scanning, design, and printing in one location.
The prosthetic, created by senior reconstructive scientist Amy Davey, mimics Richards' hair colour, eye colour, and skin. “Surface scanning patients for prosthetics means that patients can be scanned while moving, and this technology can use that movement to aid the prostheses to accommodate movement,” Davey explained.
Richards admitted the process was “not the most pleasant” and that he initially felt vulnerable. However, he said he was glad he followed through with the treatment. “I have always said no matter what treatment is offered, if I think there’s a benefit and the risks aren’t too high, I will try anything,” he added.
The driver was sentenced to three years in prison and banned from driving for seven years, but was released after 18 months for good behaviour. Richards expressed disappointment, saying: “I very nearly lost my life and have to live with all the pain from my injuries on a daily basis.”
