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Fully 3D Printed Bone Implant Used in Total Ankle Replacement Surgery

January 1, 2024

Holy Name Medical Center in New Jersey has recently achieved a milestone in orthopedic patient care by successfully performing its first surgery using a custom 3D printed bone implant. Dr. Peter Iannuzzi, a podiatric surgeon specializing in foot and ankle surgery at Holy Name, led the procedure on a patient experiencing chronic pain and difficulty walking.

The surgery is a significant advancement in orthopedics for the center, offering enhanced visual insights into a patient’s anatomy through advanced imaging. Dr. Iannuzzi leveraged this technology to create a personalized 3D printed titanium alloy bone and a new ankle joint, tailored to meet the specific needs of the patient. The process involved removing the patient’s existing bone at the top of the foot and replacing it with the 3D printed implant.

Fully 3D Printed Bone Implant Used in Total Ankle Replacement Surgery
Part of the implant. (Image Credit: Holy Name Medical Center)

One of the notable advantages of the 3D printing procedure is the improved preoperative planning enabled by three-dimensional visualization of the patient’s foot and ankle. This meticulous planning allows for more accurate surgical strategies, contributing to an overall enhanced patient experience.

By utilizing the visualization the medical team crafted a bespoke bone, navigating intricate areas with heightened precision. This not only minimizes the risk of complications but also ensures optimal outcomes for the patient. The successful completion of this surgery signifies a significant leap forward in the field of orthopedic care, showcasing the potential of 3D printing technology in revolutionizing surgical approaches and improving patient outcomes.

“The ability to replicate a bone through this 3D procedure marks a significant milestone in patient care,” said Iannuzzi.

“We are now equipped with an unparalleled tool to advance surgical interventions, ultimately providing our patients with better outcomes and improved quality of life.”

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About the author | Phillip Keane
Phillip is an aerospace engineer from UK. He is a graduate of Coventry University (UK), International Space University (France) and Nanyang Technological University (Singapore), where he studied Advanced Manufacturing at the Singapore Centre for 3D Printing.
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