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A man who lost half of his face when a drunk driver smashed in to him as he cycled with friends has been given a confidence boosting lifeline - a 3D printed prosthetic to hide his heartbreaking disfigurements.
Dave Richards, 75, was enjoying a trip out with pals near his home in Devon when he was caught up in a horrific road traffic accident on the A303 near Mere in July 2021.
Mr Richards was left with third-degree burns - where every layer of skin, down to the fat and muscle is affected - to one side of his face.
Upon impact, the grandfather-of-four was dragged beneath the car, suffering a string of brutal injuries which damaged his back and pelvis and left him with multiple broken ribs on one side of his body.
He was rushed to Bristol Royal Infirmary, where he was told he was lucky to be alive.
As he was scraped along the tarmac at speed, parts of his upper face, nose and neck were torn from his skull, leading surgeons with no choice but to remove his eye and attach a flap of skin over the half of his face which had been damaged.
Mr Richards said: 'The surgeons tried to save my eye but they were worried any infection could spread from my eye down the optic nerve to the brain so the eye was removed.
'The decision was then made to go for free flap, taking tissue with blood arteries and veins and plumbing it into my neck, the flap completely covering the side of my face.'
During his recovery - during which he needed two secondary operations to loosen scar tissues of the flap - he was referred to Reconstructive Prosthetics, which has just opened The Bristol 3D Medical Centre.
It is the first of its kind in the UK to have 3D scanning, design and printing of this kind in a single NHS location.
The centre, based in Frenchay, Bristol, provides scientific and technical support to trauma patients through state-of-the-art digital technology and specialist reconstructive expertise.
As part of his treatment, Mr Richards received a 3D prosthesis that fits the space on his face and mimics his hair colour, eye colour and skin.
He said: 'I was an outpatient before we even started talking about doing anything related to this, but I was interested.
'When 3D capability came along, it opened up a whole range of possibilities.'
Mr Richards said working with the centre has been a 'surreal' experience, which has helped him with his confidence and rehabilitation.
'It is not the most pleasant of processes - they relied on various molds and wax impressions from manual processes, they they took lots of photos for a record of how it looked, and there was lots involved in making the molds and casts on your face by covering your nose and mouth.
'In the early days of my recovery, I felt very vulnerable, and would not expose myself to social situations.
'It took me a long time to feel comfortable about my image, how I thought people looked at me and what they thought of me - but I have come a long way in that respect.
'I was keen to explore anything that could be done to alter the visual aspects of my injuries to give me more confidence.'
Mr Richards continues to visit the the Bristol 3D Medical Centre, and he has also received a large orbital prosthesis and neck scar splints to help soften scar tissue.
He said: 'After wearing the neck brace for a week, which was produced using their 3D technology, I was amazed.
'It definitely has helped because it has put pressure on the scar line, softening the tissue and making life easier to wear my face prosthesis.'
The dedicated family-man said despite his initial 'skeptical' feelings towards this treatment, he is happy he has followed through.
Mr Richards continues to have treatment to ease the scar tension and he may also need further surgery at some stage.
He said: 'I'm glad I've followed this treatment process as it has got me to where I am today.
'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 and have a go and that's still the case.
'I always weigh up whether the benefits outweigh the risk, I had that on day one.'
Amy Davey, Senior Reconstructive Scientist at NBT, said: '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.
'The 3D printers used involve advanced plastic resins whose properties allow direct application to the skin, with materials that are safe against the skin for long periods.
'Another printer at the centre has the ability to produce materials that closely resemble those of the bones themselves, allowing a far more "natural" implant.
'3D scanning over time can be useful in quantifying a patient's progress and enabling any necessary adjustments to be carried out, particularly for treating and monitoring scars.'
The man who caused the accident was sentenced to three years and banned from driving for seven years.
However, it is believed he was released after one-and-a-half years for good behaviour and as he pleaded guilty from the start.
Mr Richards added: 'As you can imagine I am not best pleased with his reduced sentence as I very nearly lost my life and have to live with all the pain from my injuries on a daily basis.'
The memory of the life-changing incident is still fresh in his mind, and Mr Richards can recall in horrifying detail the moment he was dragged beneath the drunk driver's car, who was allegedly speeding, and using his mobile phone.
He said: 'My two friends got hit, and were thrown clear of the car, but I got trapped under the car, and was rolled along, with the engine and exhaust burning through one side of my body and the other side being crushed by the car.'
The most famous case of facial reconstructive surgery is that of Charla Nash, who was left bleeding to death on her best friend's lawn after her pet chimpanzee, Travis, went berserk, gnawing off her hands and face.
In February 2009, Ms Nash, now 71, was attacked at Sandra Herold’s home in Connecticut.
The chimp ripped off her nose, lips, eyelids and hands - despite Herold hitting the crazed beast with a shovel and stabbing him in the back with a large knife.
After police arrived at the scene and shot the animal, Charla, severely disfigured from the attack, was rushed to hospital, left fighting for her life.
In 2011, she underwent a full face transplant at Brigham and Women’s Hospital - the hospital's third-ever procedure of its kind - and was fitted with glass eyes.
Earlier this year, 16 years on from the attack, Charla said the face transplant 'brought my life back' as she expressed gratitude to the surgeons.