Patient-Specific Cutting Jig for Distal Femur Tumor Resection

Patient overview

A 50-year-old male presented with significant pain and discomfort in the left knee, particularly during movement.

Preoperative CT imaging revealed the precise location, size and morphology of a tumour in the left distal femur. Because of the tumour’s position — and the need for accurate bone resection followed by reconstruction with a partial femoral implant — precise surgical planning was essential.

To facilitate accurate tumour removal, a patient-specific surgical osteotomy guide was designed around the patient’s individual anatomy and tumour characteristics.

Surgical planning

Working closely with the surgeon, the Jajal Medical design team developed a detailed patient-specific surgical plan.

• Preoperative CT imaging and 3D anatomical reconstruction were used to visualise the distal femur and pinpoint the tumour.
• The tumour boundaries were evaluated to determine the required osteotomy planes and resection margins.
• A custom cutting jig was designed to conform precisely to the patient’s distal femoral anatomy.
• Guide geometry, cutting slots and fixation provisions were tailored to the planned surgical approach and intraoperative accessibility.
• The virtual surgical plan and guide design were reviewed to confirm positioning and execution before surgery.

Patient-specific cutting jig

The custom cutting jig was developed to give the surgeon a precise and reproducible guide for tumour resection.

Key features of the design: patient-specific geometry matched to the distal femoral anatomy; cutting slots positioned to the planned osteotomy planes; dedicated fixation holes for stabilisation with K-wires; placement optimised for the surgical approach and intraoperative accessibility; and a form intended to support accurate resection and preparation for subsequent reconstruction.

Surgical procedure

During surgery the custom cutting jig was positioned onto the distal femur according to the preoperative plan.

• The guide was stabilised using K-wires through the dedicated fixation holes.
• Once securely positioned, the surgeon performed the osteotomy through the predefined cutting slots.
• The patient-specific guide helped maintain the planned cutting orientation and facilitated accurate removal of the tumour-bearing bone.
• Following resection, the femur was prepared for further reconstruction according to the surgeon’s requirements.

Clinical impact

This case demonstrates the value of patient-specific surgical guides in complex orthopaedic oncology procedures.

By combining CT-based 3D anatomical reconstruction, virtual surgical planning and customised guide design, Jajal Medical provided a solution tailored to the patient’s anatomy and tumour location.

The custom cutting jig supported accurate osteotomy, controlled tumour resection and efficient preparation for subsequent reconstruction — helping translate the preoperative surgical plan into the operating room with greater precision.