Clinical Application of FDM 3D Printing in Surgery and Traumatology: A Systematic Review

This systematic review aimed to summarize current clinical and experimental applications of Fused Deposition Modeling (FDM) 3D printing in surgery and traumatology.

Following PRISMA 2020 guidelines, a systematic search was performed in PubMed®, Scopus®, and Web of Science™ for English-language articles published between January 2020 and March 2025. Studies describing the use of FDM printing in surgical or traumatological contexts were included. Data extraction was conducted independently by three reviewers, and inclusion was determined when at least one reviewer supported it.

Out of 1,691 initially identified records, 35 studies met the inclusion criteria. Identified applications clustered into five thematic domains: surgical planning and patient-specific instruments, surgical training and simulation, biomaterials and tissue engineering, device development and prototyping, and comparisons of printing technologies and materials. FDM printing proved effective for preoperative visualization, educational modeling, and rapid prototyping of patient-specific tools, though heterogeneity in methodology and reporting limited direct comparison.

FDM 3D printing represents a versatile and increasingly accessible tool across surgical disciplines. Despite its lower resolution, its cost-effectiveness, ease of use, and expanding range of medical-grade materials make it a practical choice for clinical and educational implementation. Further standardization and validation are essential for broader clinical integration.