Sternectomy Reconstruction Using a Customized Three-Dimensional-Printed Polyetheretherketone Implant

Area of Science:

• Cardiothoracic Surgery
• Biomaterials Engineering
• Medical Device Design

Background:

• Complex sternal and chest wall defects pose significant reconstructive challenges, requiring restoration of rigidity, organ protection, and functional recovery.
• Current treatment options involve various materials, but optimal solutions for large defects remain an area of active research.
• Patient-reported outcomes like pain, clicking, and respiratory function are critical metrics for successful reconstruction.

Observation:

• A 60-year-old male presented with a debilitating post-sternectomy defect.
• The patient underwent reconstruction utilizing a custom, three-dimensional (3D)-printed polyetheretherketone (PEEK) implant combined with pectoralis muscle flaps.
• The perioperative period was uneventful, with no reported complications.

Findings:

• The patient experienced significant pain reduction and subjective improvements in chest wall stability and respiratory function post-reconstruction.
• The use of a 3D-printed PEEK implant demonstrated a viable and safe method for addressing complex cardiothoracic defects.
• PEEK offers notable benefits compared to other reconstructive materials documented in existing literature.

Implications:

• This case highlights the potential of 3D-printed PEEK implants as an effective solution for challenging sternal and chest wall reconstructions.
• Further research into PEEK's application in cardiothoracic surgery may lead to improved patient outcomes and expanded treatment possibilities.
• The successful symptom relief in this patient underscores the value of personalized, advanced material solutions in reconstructive surgery.