Engineering enables smart implants

3D printing Engineering enables smart implants

2024-11-18 Source: PTC | Translated by AI 1 min Reading Time

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A fully patient-specific scapula implant for a young cancer patient was developed by a team of experts. They relied on additive manufacturing, digitization, and medical imaging.

A team of experts jointly developed a titanium scapula implant that is precisely tailored to the patient's anatomy.(Image: Tel Aviv Medical Center) — A team of experts jointly developed a titanium scapula implant that is precisely tailored to the patient's anatomy.
(Image: Tel Aviv Medical Center)

In a joint project, a team of experts from the Tel Aviv Medical Center, PTC, and Hexagon created a fully patient-specific scapula implant for a 16-year-old cancer patient. The team used additive manufacturing and medical imaging to design and manufacture a titanium scapula implant precisely tailored to the patient's anatomy.

The operation went as planned, the personalized implant fitted seamlessly, and the patient regained her mobility within a few days.(Image: Tel Aviv Medical Center) — The operation went as planned, the personalized implant fitted seamlessly, and the patient regained her mobility within a few days.
(Image: Tel Aviv Medical Center)

The experts performed a 3D segmentation of the tumor and the surrounding bone to enable effective reconstruction. A digital twin of the anatomical model was created and printed at a 1:1 scale to support preoperative planning and delineate the resection margins. At the same time, a custom 3D-printed implant was designed with PTC's CAD software Creo to anchor the remaining muscle stumps and reconstruct the joints.

The key requirements and challenges included:

Preserve the patient's original anatomical volume, shape, and kinematics
Optimize the mechanical properties of the implant while simultaneously reducing weight
Provide an optimal set of anchoring points for muscle attachment
Implement an advanced lattice structure to facilitate the integration of connective tissue and muscles while avoiding supports and distortions by using Creo Design for Metal Additive Manufacturing
Introduce minimal surfaces for smooth joint kinematics

Bioactive printed implants are the future of implants! The development of complex implantable printed materials, combined with powerful additive manufacturing and simulation software, allows us to introduce intelligent implants into the world of surgery. These implants interact with the tissue to optimize their survival in the body, ensure a perfect fit, and promote tissue growth.

Dr. Solomon Dadia, Head of the Department of Surgical Innovation and 3D Printing, Tel Aviv Sourasky Medical Center

The collaboration between the Tel Aviv Medical Center, PTC, and Hexagon is a milestone where engineering meets personalized medicine.(Image: PTC) — The collaboration between the Tel Aviv Medical Center, PTC, and Hexagon is a milestone where engineering meets personalized medicine.
(Image: PTC)

The team relied on the use of mechanical simulations during development to check the load capacity of the implant for shoulder and arm movements. Thanks to Hexagon's Simufact Additive solution, processes and manufacturability were simulated in advance, reducing the number of printed samples. Using Hexagon's Vgstudio, the print quality was checked for certification.

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Date: 08.12.2025

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