Custom Tibia Implant for Complex Tibial Reconstruction

Patient Overview: 

A 70-year-old male patient presented with a fractured right tibia following a lower limb injury. Due to the complexity and extent of the fracture, conventional fixation options were insufficient to restore proper limb alignment and function. 

To ensure anatomical accuracy and long-term stability, the surgical team recommended a custom tibia implant to precisely reconstruct and align the fractured tibia.

Surgical Planning: 

In close collaboration with the surgeon, the Jajal Medical 3D design team performed a detailed digital preoperative plan to ensure precision and predictability. 

• A CT-based 3D segmentation of both tibias was performed. 

• The healthy left tibia was mirrored and registered with the fractured right tibia to achieve ideal anatomical alignment and equal limb length. 

• Based on this alignment, a custom tibia implant was meticulously designed to match the patient’s unique bone geometry and fixation needs. 

Surgical Planning: 

In close collaboration with the surgeon, the Jajal Medical 3D design team performed a detailed digital preoperative plan to ensure precision and predictability. 

• A CT-based 3D segmentation of both tibias was performed. 

• The healthy left tibia was mirrored and registered with the fractured right tibia to achieve ideal anatomical alignment and equal limb length. 

• Based on this alignment, a custom tibia implant was meticulously designed to match the patient’s unique bone geometry and fixation needs. 

   

3D-Printed, Patient-Specific Tibia Implant: 

The custom tibia implant was manufactured using advanced metal 3D printing technology with medical-grade titanium (Ti6Al4V), ensuring exceptional strength, biocompatibility, and precision fit. 

Key Features of the Custom Tibia Implant:

• Locking screw configuration for stable fixation and load transfer. 

• Intramedullary peg in the distal tibia to enhance rigidity and minimize micromotion. 

• Porous lattice structure at bone-contact regions to promote osseointegration and long-term biological fixation. 

This customized implant provided the surgeon with an accurate, patient-matched solution that ensured optimal alignment, stability, and biomechanical restoration. 

Post-op Outcome: 

The custom tibia reconstruction was successfully performed. The implant fit precisely along the realigned tibial structure, achieving excellent fixation and anatomical balance between both limbs. 

Early postoperative results demonstrated stable bone integration, proper load distribution, and improved functional recovery. 

         

Clinical Impact: 

This case underscores the transformative role of custom 3D-printed orthopedic implants in managing complex tibial fractures where conventional fixation methods fall short. 

By combining advanced imaging, precise 3D design, and additive manufacturing, Jajal Medical enabled a fully personalized reconstruction that restored limb length, stability, and function — exemplifying the future of patient-specific orthopedic care.