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Updated: May 10, 2026

3D Planning and Printing of Patient Specific Implants for Reconstruction of Bony Defects
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Surgeon-Led Surgical Device Development Using Computer-Aided 3D Modeling.

JungHoon Kang1, Seung Hwan Yoon2, Je Hoon Jeong1

  • 1Department of Neurosurgery, Soonchunhyang University Bucheon Hospital, Bucheon-si, Gyeonggi-do, Republic of Korea.

Surgical Innovation
|May 8, 2026
PubMed
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Surgeon-designed 3D computer-aided design (CAD) models streamline the creation of custom surgical instruments. This workflow successfully developed and integrated new tools, with some replacing standard instruments in spine surgery.

Area of Science:

  • Orthopedics
  • Biomedical Engineering
  • Surgical Innovation

Background:

  • Unmet clinical needs in spine surgery necessitate novel instrument designs.
  • Conventional instrument development can be lengthy and may not fully address specific surgical challenges.

Purpose of the Study:

  • To outline a surgeon-led workflow for developing customized surgical instruments using computer-aided design (CAD).
  • To evaluate the clinical utility and adoption of these novel devices in spine surgery.

Main Methods:

  • Surgeons identified clinical needs and created 3D CAD models using Autodesk Fusion 360®.
  • Manufacturer engineers refined models for production, incorporating patient-specific imaging data.
  • Developed instruments were used clinically for at least six months and assessed via usability surveys.
Keywords:
ergonomics and/or human factors studyneurosurgerysimulationthe business of surgery

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Last Updated: May 10, 2026

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Main Results:

  • Custom windowed reamer and flexible-tip retractor received high satisfaction scores and are now standard tools.
  • A retroperitoneal/extrapleural retractor also showed high utility.
  • Other developed instruments had lower satisfaction and remain in mixed use.

Conclusions:

  • Surgeon-generated 3D CAD models facilitate efficient communication and rapid development of custom surgical instruments.
  • This approach enables the creation of devices that address specific intraoperative needs and can replace standard tools.
  • It provides a practical method for translating clinical needs into manufacturable designs for surgical practice.