When 75-year-old Devon cyclist Dave Richards looks in the mirror today, he sees more than a survivor—he sees a testament to medical innovation and human resilience. In July 2021, while cycling near Mere with two friends, a drunk driver distracted by his phone ploughed into them at high speed. Dave’s friends were thrown clear, but he was trapped beneath the vehicle, the engine burning one side of his face while the other was crushed.
The accident left him with full-thickness facial burns, a broken back, shattered ribs, and a fractured pelvis. Surgeons fought to save his eye but ultimately had to remove it to prevent infection from spreading to his brain. He underwent a complex free-flap surgery, followed by multiple procedures to release tightened scar tissue.
During his recovery at Bristol Royal Infirmary, Dave learned about a groundbreaking option: a custom, lifelike prosthesis created through the NHS’s new 3D Medical Centre at Frenchay. He became one of the first patients—and the first to receive a 3D-printed facial prosthesis that perfectly matched his skin tone, hair, and even eye color.
The process was grueling. Mold-making involved layers of wax, casts, and claustrophobic impressions over his nose and mouth. Later, a 3D-printed neck splint helped soften scar tissue, making the prosthesis more comfortable. “After a week, I was amazed,” Dave recalled.
Yet the physical recovery was only part of the challenge. “In the early days, I felt very vulnerable,” he admitted. “I struggled with my appearance and how people might perceive me. It took a long time to rebuild that confidence.”
Resilience has always been part of Dave’s nature. Just five months after the crash, he climbed back onto a bike indoors, slowly regaining strength. He remains frustrated by the drunk driver’s reduced sentence—only 18 months served. “I very nearly lost my life,” he said. “I live with the pain every day.”
Still, optimism guides him forward. “I’m glad I followed this treatment process—it’s brought me to where I am today. I’ve always said: if there’s a benefit and the risks aren’t too high, I’ll try anything.”
For Dave Richards, hope isn’t abstract—it’s engineered, printed, worn, and carried forward with every mile he rides.
