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Additive Manufacturing in Orthopaedic Trauma: Current Evidence and Applications
Nikolaos A Stavropoulos1, Fotios Kantas2, Dimitrios V Papadopoulos1
1Second Department of Orthopaedic Surgery, School of Medicine, National and Kapodistrian University of Athens, "Konstantopouleio" General Hospital, 14233 Athens, Greece.
Medicina (Kaunas, Lithuania)
|March 28, 2026
Summary
Three-dimensional (3D) printing in orthopaedic trauma offers benefits like reduced operative time with anatomical models and improved accuracy with patient-specific surgical guides (PSSGs). Further research is needed for 3D-printed implants and external fixators.
Area of Science:
- Orthopaedic Surgery
- Additive Manufacturing
- Biomedical Engineering
Background:
- Additive manufacturing (3D printing) is a rapidly advancing field in orthopaedics, enabling the creation of complex 3D structures.
- Its clinical value is recognized for ease of production and cost-effectiveness, but evidence in trauma applications is varied.
- This review focuses on the clinical uses of 3D printing within traumatology.
Purpose of the Study:
- To review and analyze the clinical applications of 3D printing in orthopaedic traumatology.
- To identify and highlight research gaps in the current literature.
- To assess the clinical applicability of four key 3D printing domains in trauma care.
Main Methods:
- A narrative review of existing literature on 3D printing in orthopaedic traumatology.
- Selection of four prevalent application domains: 3D-printed anatomical models, patient-specific surgical guides (PSSGs), 3D-printed implants, and temporary 3D-printed external fixation devices.
- Analysis of the clinical implementation and outcomes for each domain.
Main Results:
- 3D-printed anatomical models demonstrated potential to decrease operative time, blood loss, and radiation exposure.
- Patient-specific surgical guides (PSSGs) improved intraoperative accuracy and outcome consistency but faced challenges in preparation time and accuracy with soft tissue changes.
- 3D-printed implants and external fixators showed feasibility, comparable mechanical properties, and lower costs, though require further multicenter validation.
Conclusions:
- 3D-printed anatomical models and PSSGs currently show the highest clinical applicability in orthopaedic trauma, particularly for preoperative planning and intraoperative guidance.
- 3D-printed implants and external fixation devices present promising avenues but necessitate more extensive research and clinical trials.
- Addressing current limitations and conducting larger studies will be crucial for broader adoption of these advanced 3D printing applications in trauma.
