Related Experiment Video
Updated: May 27, 2026

3D Planning and Printing of Patient Specific Implants for Reconstruction of Bony Defects
Published on: August 4, 2020
Reconstruction of frontal bone using specific implant polyether-ether-ketone
Edevaldo Tadeu Camarini1, Jorge Kaluf Tomeh, Rafael Rodrigues Dias
1Departamento de Odontologia Avenida Mandacaru, State University of Maringá, Maringá, Paraná, Brazil. edevaldocamarini@wnet.com.br
This study presents a case where a PEEK implant was used to reconstruct a frontal bone defect. The implant was digitally designed to fit the patient's specific needs. The surgery was efficient, with minimal intraoperative adjustments. Postoperative imaging showed the implant was properly placed. The results suggest that PEEK implants can be effective in craniofacial surgery. The material's properties support its use in such procedures. The study highlights the benefits of using digitally designed implants. It may help guide future approaches to similar reconstructions.
Area of Science:
- Craniofacial surgery
- Biomedical materials
- Polymer implant applications
Background:
Craniofacial defects can lead to both functional and psychological challenges. Earlier surgical approaches often neglected the restoration of bone contours, treating them as secondary concerns. Over time, the focus has shifted toward reconstructing both form and function. Digital design and alloplastic materials have emerged as key innovations in this field. Alloplastic implants are now recognized for their role in reducing intraoperative adjustments. These implants also help shorten surgical duration. However, the choice of material remains a critical factor in outcomes. PEEK has gained attention due to its favorable mechanical and biocompatible properties.
Purpose Of The Study:
This study aimed to present a clinical case where PEEK was used for frontal bone reconstruction. The goal was to demonstrate the application of PEEK in a specific implant scenario. The focus was on evaluating the effectiveness of PEEK in restoring bone contours. The study also sought to highlight the advantages of using digitally designed implants. By using PEEK, the researchers aimed to reduce intraoperative manipulation. They also intended to assess the material's suitability in craniofacial surgery. The case was selected to illustrate the practical application of PEEK implants. The findings could inform future approaches to similar reconstructions.
Main Methods:
The study involved a single case of frontal bone reconstruction. A PEEK implant was custom-designed for the patient. The implant was fabricated using the PEEK-PSI system from Synthes. Digital imaging and planning were used to model the implant. The surgical procedure followed standard protocols for craniofacial reconstruction. Intraoperative adjustments were minimized due to the pre-planned implant. Postoperative imaging confirmed the implant's fit and positioning. The patient's recovery and outcomes were monitored over time.
Main Results:
The PEEK implant was successfully placed in the frontal bone defect. The implant's shape matched the preoperative digital design. No major intraoperative adjustments were needed. The surgery duration was shorter than typical for such procedures. Postoperative imaging showed proper alignment and integration. The patient experienced no immediate complications. The implant remained stable during the follow-up period. The results suggest that PEEK implants can be effective in frontal bone reconstruction.
Conclusions:
The study demonstrated the viability of PEEK implants in frontal bone reconstruction. The material's properties supported the implant's structural and functional role. The use of a digitally designed implant reduced intraoperative manipulation. The case highlights the potential of PEEK in craniofacial surgery. The authors suggest that PEEK implants may improve surgical efficiency. They also note the material's compatibility with digital planning tools. The findings align with prior research on PEEK's biocompatibility. The study supports further exploration of PEEK in similar clinical scenarios.
Frequently Asked Questions
The main outcome is reduced intraoperative manipulation and shorter surgery duration due to pre-planned implant design.
PEEK combines strength, stiffness, durability, and resistance, while also showing biocompatibility in prior studies.
Digital design allows for precise implant shaping, minimizing adjustments during surgery and improving fit.
Postoperative imaging confirmed the implant's proper fit and positioning after surgery.
The PEEK-PSI system enabled a specific implant design tailored to the patient's frontal bone defect.
The authors suggest that PEEK may improve surgical efficiency and support further exploration in similar cases.

