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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.

Post-traumatic zygomatic osteotomy, fracture reduction, and orbital floor reconstruction pose many challenges for achieving a predictable, accurate, safe, and aesthetically pleasing result. This paper aims to describe the successful application of computer-aided design (CAD) and additive manufacturing (AM) to every stage of the process – from planning to surgery.

A multi-disciplinary team was used – comprising surgeons, prosthetists, technicians, and designers. The patient’s computed tomography scan data were segmented for bone and exported to a CAD software package. Medical models were fabricated using AM; for diagnosis, patient communication, and device verification. The surgical approach was modelled in the virtual environment and a custom surgical cutting guide, custom bone-repositioning guide, custom zygomatic implant, and custom orbital floor implant were each designed, prototyped, iterated, and validated using polymer AM prior to final fabrication using metal AM.

Post-operative clinical outcomes were as planned. The patient’s facial symmetry was improved, and their inability to fully close their eyelid was corrected. The length of the operation was reduced relative to the surgical team’s previous experiences. Post-operative scan analysis indicated a maximum deviation from the planned location for the largest piece of mobilised bone of 3.65 mm. As a result, the orbital floor implant which was fixed to this bone demonstrated a maximum deviation of 4.44 mm from the plan.

This represents the first application of CAD and AM to every stage of the process for this procedure – from diagnosis, to planning, and to surgery.