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.

This implant represents a significant leap in personalised orthopaedic care, combining biomechanical precision with anatomical customisation.

• 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

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 personalised Hemi-Fill solution, underscoring the vital role of tailored implants and pre-surgical accuracy in managing complex shoulder pathologies.