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Chest wall reconstruction of large oncological defects following resection is challenging. Traditional management involves the use of different materials that surgeons creatively shape intraoperatively to restore the excised anatomy. This is time-consuming, difficult to mould into shape and causes some complications such as dislocation or paradoxical movement. This study aims to present the development and clinical implantation of a novel custom-made three-dimensional (3D) laser melting titanium alloy implant that reconstructs a large chest wall resection and maintains the integrity of the thoracic cage.

The whole development process of the novel implant is described: design specifications, computed tomography (CT) scan manipulation, 3D computer-assisted design (CAD), rapid prototyping, final manufacture and clinical implantation. A multidisciplinary collaboration in between engineers and surgeons guided the iterative design process.

The implant provided excellent aesthetical and functional results. The virtual planning and production of the implant prior to surgery reduced surgery time and uncertainty. It also improved safety and accuracy. The implant sited nicely on the patient anatomy after resection following the virtual plan. At six months following implantation, there were no implant-related complications of pain, infection, dislocation or paradoxical movement. This technique offered a fast lead-time for implant production, which is crucial for oncological treatment.

More cases and a long-term follow-up are needed to confirm and quantify the benefits of this procedure; further research is also required to design a solution that better mimics the chest wall biomechanics while preventing implant complications.

The authors present a novel custom thoracic implant that provided a satisfactory reconstruction of a large chest wall defect, developed and implanted within three weeks to address a fast-growing chondrosarcoma. Furthermore, the authors describe its development process in detail as a design guideline, discussing potential improvements and critical design considerations so that this study can be replicated for future cases.

The purpose of the paper was to present a specific case study of how 3D printing was introduced in the chest wall construction process of a specific patient with unique medical condition. A life-size 3D model of the patient’s chest wall was 3D printed for pre-surgical planning. The intent was to eliminate the need for operative exposure to map the pathological area. The model was used for preoperative visualization and formation of a 1-mm thick titanium plate implant, which was placed in the patient during chest wall reconstructive surgery. The purpose of the surgery was to relive debilitating chronic pain due to right scapular entrapment.

The patient was born with a twisted spine. Over time, it progressed to severe and debilitating scoliosis, which required the use of a thoracic brace. Computerized tomography (CT) data were converted to a 3D printed model. The model was used to size and form a 1-mm thick titanium plate implant. It was also used to determine the ideal location for placement of the plate during thoracotomy preoperatively.

The surgery, aided by the model, was successful and resulted in a significantly smaller incision. The techniques reduced invasiveness and enabled the doctors to conduct the procedure efficiently and decreased surgery time. The patient experienced relief of the chronic debilitating pain and no longer need the thoracic brace.

The 3D model facilitated pre-operative planning and modeling of the implant. It also enabled accurate incision locations of the thoracotomy site and placement of the implant. Although chest wall reconstruction surgeries have been undertaken, this paper documents a specific case study of chest wall construction fora specific patient with unique pathological conditions.

Medical devices are undergoing rapid changes because of the increasing affordability of advanced technologies like additive manufacturing (AM) and three-dimensional scanning. New avenues are available for providing solutions and comfort that were not previously conceivable. The purpose of this paper is to provide a comprehensive review of the research on developing prostheses using AM to understand the opportunities and challenges in the domain. Various studies on prosthesis development using AM are investigated to explore the scope of integration of AM in prostheses development.

A review of key publications from the past two decades was conducted. Integration of AM and prostheses development is reviewed from the technologies, materials and functionality point of view to identify challenges, opportunities and future scope.

AM in prostheses provides superior physical and cognitive ergonomics and reduced cost and delivery time. Patient-specific, lightweight solutions for complex designs improve comfort, functionality and clinical outcomes. Compared to existing procedures and methodologies, using AM technologies in prosthetics could benefit a large population.

This paper helps investigate the impact of AM and related technology in the field of prosthetics and can also be viewed as a collection of relevant medical research and findings.

Poland’s syndrome patients often seek medical interventions to improve their aesthetic appearances. Design and manufacturing technologies make it possible to produce custom-made implants for such medical conditions. The purpose of this study was to compare the 3D digital geometries that were designed using Magics and Geomagic^® Freeform^® for two anonymous case studies of Poland’s syndrome patients.

Computed tomography data were acquired and processed in Mimics^® to isolate the pectoralis muscles in STL file format. STL files were imported into Magics and Geomagic^® Freeform^® to design 3D digital geometries. Thereafter, comparative analyses were performed of the respective 3D digital geometries.

The angle between the vertical and oblique planes for both sides of the thorax was 6.5° for the female and 14° for the male. The surface areas and volumes of the geometries for the female were smaller than the male. Deviation analyses between the healthy side and reconstructed side of a thorax showed that 73 per cent of the test points for Magics and 78 per cent for Geomagic^® Freeform^® fell in the nominated tolerance region of >−5 and <+5 mm for the female. For the male, it was 83 per cent for Magics and 88 per cent for Geomagic^® Freeform^®.

Geomagic^® Freeform^® provides a more versatile design environment; however, the STL editor Magics may be an option to design 3D geometries for less intricate and less contoured implants.

This was a first attempt to compare the 3D geometries for Poland’s syndrome designed with an STL editor to those designed with a computer-aided design program.

The purpose of this study is to identify, analyse and model the post-processing barriers of 3D-printed medical models (3DPMM) printed by fused deposition modelling to overcome these barriers for improved operational efficiency in the Indian context.

The methodology used interpretive structural modelling (ISM), cross-impact matrix multiplication applied to classification (MICMAC) analysis and decision-making trial and evaluation laboratory (DEMATEL) to understand the hierarchical and contextual relations among the barriers of the post-processing.

A total of 11 post-processing barriers were identified in this study using ISM, literature review and experts’ input. The MICMAC analysis identified support material removal, surface finishing, cleaning, inspection and issues with quality consistency as significant driving barriers for post-processing. MICMAC also identified linkage barriers as well as dependent barriers. The ISM digraph model was developed using a final reachability matrix, which would help practitioners specifically tackle post-processing barriers. Further, the DEMATEL method allows practitioners to emphasize the causal effects of post-processing barriers and guides them in overcoming these barriers.

There may have been a few post-processing barriers that were overlooked by the Indian experts, which might have been important for other country’s perspective.

The presented ISM model and DEMATEL provide directions for operation managers in planning operational strategies for overcoming post-processing issues in the medical 3D-printing industry. Also, managers may formulate operational strategies based on the driving and dependence power of post-processing barriers as well as the causal effects relationships of the barriers.

This study contributes to identifying, analyzing and modelling the post-processing barriers of 3DPMM through a combined ISM and DEMATEL methodology, which has not yet been reviewed. This study also contributes to decision makers developing suitable strategies to overcome the post-processing barriers for improved operational efficiency.

Breast cancer is the most diagnosed type of cancer in the world, and mastectomies to remove tumors are still common. An external breast prosthesis (EBP) can be used to minimize the asymmetry, due to the ablation. Some governments do not cover costs of that assistive technology, and women end up using socks and fabric pockets filled with seeds, to simulate the volume lost in the surgery. This study aims to offer to those women a decent solution, ergonomic, but still affordable.

The authors interviewed 20 mastectomized Brazilian women, listened to their relate and 3D scanned them, to give rise to personalized external lightweight breast prostheses. The authors used free software for computer-aided design and computer-aided manufacturing, and low-cost 3D printers. From the strategy of bespoke products, this study generalized the method, to conceive mass customized prostheses, in a compromise solution that reduces personalization, conserving the best features of design.

This study achieved a method to manufacture ergonomic, bespoke external breast prostheses, using low-cost technology. Previous literature made them using expensive scanners, software and printers.

The authors validated this method during pandemic, which restricted the number of patients the authors could have access to. This impacted authors’ possibility to work on matching the color of the final product and real skin. The authors understood, though, that precision of color, in the final product, is challenging, because of the peculiar aspects of human skin.

Using the method the authors proposed, personalized external breast prostheses can be manufactured using low-cost resources, democratizing better quality of life for more breast cancer survivors.

Among thoracic malformations, pectus deformities have the highest incidence and can result in a wide range of severe and mild clinical manifestations. Recently, the treatment of pectus deformities is shifting from traditional approaches toward customized solutions. This occurs by leveraging innovative rapid prototyping tools that allow for the design and fabrication of patient-specific treatments and medical devices. This paper aims to provide a comprehensive view of the growing literature in this area to analyze the progress made in this direction.

The search was performed on major search engines through keywords inherent to reverse engineering (RE) and additive manufacturing (AM) technologies applied to pectus deformities and related treatments, selecting 54 papers. These were analyzed according to the addressed pathology, the hardware and software tools used and/or implemented and their integration within the clinical pathway.

First, the analysis led to analyze and divide the papers according to how RE and AM technologies are applied for surgical and non-surgical treatments, pathological assessment and preoperative simulation and planning. Second, all papers were considered within the typical rapid prototyping framework consisting of the three phases of three-dimensional (3D) scanning, 3D modelling and 3D printing.

To the best of the authors’ knowledge, to date, no survey has provided a comprehensive view of innovative and personalized treatment strategies for thoracic malformations; the present work fills this gap, allowing researchers in this field to have access to the most promising findings on the treatment and evaluation of pathology.

The purpose of this paper is to design and manufacture an intelligent 3D printed sensor to monitor the re-occurrence of diaphragmatic hernia (DH; after surgery) in bovines as an Internet of Things (IOT)-based solution.

The approach used in this study is based on a bibliographic analysis for the re-occurrence of DH in the bovine after surgery. Using SolidWorks and ANSYS, the computer-aided design model of the implant was 3D printed based on literature and discussions on surgical techniques with a veterinarian. To ensure the error-proof design, load test and strain–stress rate analyses with boundary distortion have been carried out for the implant sub-assembly.

An innovative IOT-based additive manufacturing solution has been presented for the construction of a mesh-type sensor (for the health monitoring of bovine after surgery).

An innovative mesh-type sensor has been fabricated by integration of metal and polymer 3D printing (comprising 17–4 precipitate hardened stainless steel and polyvinylidene fluoride-hydroxyapatite-chitosan) without sacrificing strength and specific absorption ratio value.

This chapter focuses on the differences that younger, middle-aged, and older women with breast cancer experience, particularly in health knowledge and treatment. These differential experiences, in part, stem from our youth oriented culture. This ideology extends into medicine and can affect day-to-day medical practice. Differential experiences are, therefore, likely to result in inequality and disparity in health and in healthcare. It is argued that older women are less empowered than their younger counterparts to display the same degree of agency. This analysis has important implications for health care professionals in the treatment of older women with breast cancer.