Abstract
Purpose Meniscal allograft transplantation can restore joint biomechanics and alleviate symptoms, but its clinical use is limited by the scarcity of size-matched, structurally intact grafts. Current two-dimensional sizing and subjective inspection in tissue banks fail to capture complex three-dimensional geometry and subtle surface defects, highlighting the need for an accurate, reliable, and practical solution for routine donor tissue evaluation. Methods We developed an integrated system combining optical 3D scanning with curvature-based analysis for 3D geometry capture and surface defect detection in meniscus allografts. System performance was validated in terms of scanner accuracy and tissue bank workflow feasibility. Results The system completes each scan within 2 versus ~ 60 min for micro-computed tomography (μCT). It demonstrated μCT-comparable accuracy (mean volume difference: 6.9%; surface deviation: 8.3%). Scanning through phosphate buffer saline (PBS)-immersed transparent bags yielded equivalent accuracy to scanning in air (mean volume difference: 7.2%; surface deviation: 12.5%). The workflow demonstrated high intra- and inter-operator reproducibility. Viability testing revealed PBS-preserved tissues maintained > 94% viability for 20 min, whereas air-exposed tissues dropped below 70% within 10 min. For defect assessment, curvature metrics reliably identified surface wear, longitudinal, and radial defects, with size measurements for wear and longitudinal tears showing equivalence (± 10% margin) to stereomicroscopy. Conclusion This portable system enables accurate and rapid 3D scanning under tissue banking conditions and quantitative surface defect detection. It supports improved graft shape matching and surface defect screening, offering a practical and scalable solution for tissue banks and clinical settings, potentially extendable to other fibrocartilaginous and osteochondral tissues.