3D Printed Jigs

3D Printed Jigs and Implants: Precision Engineering

Standard orthopaedic implants are designed for "average" populations. In complex joint care and oncology, the average does not exist. We utilize high-resolution CT and MRI data to design and print customized surgical tools and titanium implants that match the specific geometry of the defect.

1. Precision Resections in Musculoskeletal Oncology (MSO)

In bone tumor surgery, the margin of error is measured in millimeters. We utilize 3D printed cutting jigs to execute resections that are both oncologically safe and biologically conservative (Figure 3, video).

• Growth Plate Sparing: For pediatric patients, these jigs allow us to remove the tumor while sparing the growth plate, preserving the child's future growth potential.

• Joint Sparing: By guiding the saw blade with sub-millimeter accuracy, we can preserve the native joint surface even when the tumor is in close proximity, avoiding the need for a total joint replacement.

2. Multi-Planar Angular Correction (Osteotomies)

Traditional osteotomy systems are typically uniplanar, limiting the surgeon's ability to correct complex deformities (Figure 1).

• Two-Plane Correction: Our 3D printed jigs facilitate accurate angular correction in two planes simultaneously.

• Predictable Alignment: By printing the correction directly into the jig, we ensure that the post-operative mechanical axis is exactly as planned, reducing the risk of joint overload or early failure.

3. Patient-Specific Instrumentation (PSI) for Total Knee Replacement

Robotic-assisted surgery is often marketed as the only way to achieve precision in Total Knee Arthroplasty. However, we utilize Patient-Specific Instrumentation (PSI) as a technically equivalent and more cost-effective alternative.

• Robotic-Level Accuracy: PSI jigs are printed to fit the patient's femur and tibia perfectly, ensuring bone cuts match the pre-operative plan with the same precision as a robot.

• Efficiency and Cost: PSI eliminates the massive capital cost and intra-operative time associated with robotic systems, providing the same high-tier result at a lower cost to the healthcare system and the patient.

4. Custom Implants for Complex Bone Loss

Standard modular implants cannot address irregular bone loss geometries caused by trauma, failed previous surgeries, or tumor resections.

• Geometric Matching: We design 3D printed titanium implants that fill the exact void of the missing bone (Figure 2).

• Structural Integrity: These custom implants provide superior primary fixation and load distribution, restoring the structural honesty of the joint in salvage scenarios.

Figure 1. By creating specialised and customised jigs 3D printed cutting guides allow very precise placement of cuts.

Figure 2. 3D printed implants very precisely fit defects created after tumor resections.

Figure 3. This is the video of a highly specialized resection and reconstruction of a bone tumor using 3D printing technology.