An orthopedic implant is a manmade device targeting to replace a joint, bone, or cartilage which are damaged or deformed by traumas or diseases. In this case the doctor may decide to replace a damaged natural part with a manufactured medical device e.g., an orthopedic implant. However, this task is not an easy one and heavily dependant on damaged area and type of bones.
Based on CT data the damaged bone and the part where the implant should be placed are being modeled.
The implant and the bone is being printed (plastic). The physical samples is provided to doctor. After feedback and correction the implant is being printed
Case 1: Orbital flaw: Talus
A young adult with a traumatic fracture-dislocation of the Talus required multiple operations over 2 years. The whole talus developed Avascular Necrosis. Attempted fusion with a locked IM-rod from the calcaneus up the fibia failed. Due to intractable pain, the patient was advised a Syme amputation that he refused. After consulting with our group, understanding the difficulty and possible risk of an ultimate BK amputation, he agreed to get a 3-D printed talar implant specifically designed for him, aiming to achieve a pan-talar fusion including a triple arthodesis with the implant, hoping to keep his foot. The surgery was performed in February 2021. The patient had an uneventful recovery, is now able to walk without pain, full weight bearing on the leg that he retains.
Process of the work
Computer tomography of the damaged bone
3D model of the bone
Designing and modeling of the implant
Planning the surgery
Designing and preparing necessary tools and screws for the surgery.
Preparation of implants
To mitigate the risk 3 different implants are ready for use.
3D printed Titanium implant: 3 different modification of the implants
Implant assembled with damaged bone
The surgery was performed in February 2021. The patient had an uneventful recovery. He is now able to walk without pain, full weight bearing on the leg that he retains.
Case 2: Orbital flaw:
H. G., 67 years old Female
29/10/2015 Right Hip total endoprosthesis performed.
11/05/2016 Left Hip total endoprosthesis performed.
2018 Severe pain in the left thigh and pelvis, swelling of the left thigh. Patient received NSAIDs and Pain Meds to no avail. With ongoing pain, the Left hip was aspirated under CT control, and obtained fluid culture revealed an infection.
02/04/2019 The Left loose and infected femoral stem was revised, lavage, drainage, & a new stem coated with antibiotic cement was inserted. Cup and liner were left in place.
27/11/2019 Second Revision, removal of all components, insertion of antibiotic spacer.
10/09/2020 Removal of the spacer only. Shortening and limp resulted with significant functional as well as acetabular bone deficiency, precluding a standard available component insertion.
[AIP was consulted at this time]
10/03/2021 Final revision was performed with a CT scan based, designed and printed/manufactured acetabular component with a new femoral stem (provided by AIP).
Presently, patient is well, ambulating with equal leg lengths and happy. No recurrence of pain or infection thus far.