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3D Planning and Printing of Patient Specific Implants for Reconstruction of Bony Defects
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Three-Dimensional Printed Custom Implants in Orthopaedic Surgery.

Max H Mccall1, Pranav Singh1, Benjamin R Wesorick2

  • 1Emory Department of Orthopaedic Surgery, Emory University.

Journal of Visualized Experiments : Jove
|December 22, 2025
PubMed
Summary
This summary is machine-generated.

This protocol details using custom 3D printed implants in orthopaedic surgery for complex bone loss. It guides clinicians through patient selection, design, and implantation, offering solutions where standard implants fail.

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Area of Science:

  • Orthopaedic Surgery
  • Biomedical Engineering
  • Materials Science

Background:

  • Three-dimensional (3D) printing offers transformative solutions in medicine, particularly for complex orthopaedic cases.
  • Standard implants are often insufficient for patients with severe bone loss or deformities.
  • Custom 3D printed implants provide a viable alternative for challenging reconstructive needs.

Purpose of the Study:

  • To outline the clinical and technical workflow for utilizing custom 3D printed implants in orthopaedic surgery.
  • To serve as a guide for clinicians integrating 3D printed custom implants into practice.
  • To expand treatment possibilities for patients requiring complex orthopaedic reconstruction.

Main Methods:

  • Detailed step-by-step protocol from patient evaluation to surgical implantation.
  • Emphasis on high-resolution CT imaging and computer-aided design (CAD) for precision.
  • Utilizes advanced manufacturing techniques like powder bed fusion and post-processing for quality assurance.

Main Results:

  • Custom 3D printed implants offer significant advantages in customization, surgical planning, and functional restoration.
  • Early results show promise for improved patient outcomes in complex orthopaedic cases.
  • The protocol addresses critical considerations like patient selection and collaborative design.

Conclusions:

  • Custom 3D printed implants represent a significant advancement in orthopaedic surgery for complex cases.
  • Continued research is needed to address limitations such as cost and long-term outcome data.
  • This protocol facilitates the integration of 3D printed implants, enhancing reconstructive capabilities.