World’s First Custom Implant for Hill Sachs Lesion

Patient Overview: 

A male patient presented with a history of chronic anterior shoulder dislocations. Advanced imaging revealed a Hill-Sachs lesion, an indentation on the postero-superolateral humeral head commonly resulting from repeated dislocations. 

 The lesion was suspected to coexist with a Bankart lesion on the glenoid rim, contributing to persistent shoulder instability. 

Considering the lesion’s depth and location, standard treatment was deemed insufficient. The design team from Jajal Medical pursued a pioneering approach: developing the world’s first custom “Fill Sachs” implant, engineered to match the patient’s unique bone anatomy. 

Surgical Planning: 

In collaboration with the Allegra Orthopedics team, Dr. David Duckworth led the planning phase with precision. 

 Using high-resolution CT imaging and advanced 3D segmentation techniques, a patient-specific implant was custom-designed to accurately reconstruct the natural curvature of the humeral head and address the bone deficit. 

3D-Printed, Patient-Specific Implant: 

The implant was manufactured using cutting-edge metal 3D printing technology with medical-grade titanium Ti6Al4V, offering optimal strength, biocompatibility, and long-term performance. 

Key Features: 

• Custom geometry matching the exact curvature and thickness needed to fill the Hill-Sachs defect 

• Porous lattice structure at the bone interface to promote superior osseointegration 

• Recessed locking screw mechanism for secure fixation and cartilage preservation 

• Mirror-polished surface enabling smooth articulation and preserving natural joint movement 

This implant represents a significant leap in personalized orthopedic care, combining biomechanical precision with anatomical customization. 

Post-op Outcome: 

The surgery was successfully completed with the implant fitting seamlessly into the defect site. Postoperative assessments indicated a marked improvement in shoulder stability and range of motion. 

Dr. David Duckworth highlighted the clinical impact of this personalized Hemi-Fill solution, underscoring the vital role of tailored implants and pre-surgical accuracy in managing complex shoulder pathologies.