Custom FTL Cup for Complex Revision Hip Replacement

Patient overview

A patient with a history of primary hip replacement presented with implant failure, leading to massive bone loss in the anterior column of the right acetabulum. Standard revision implants were unsuitable due to the severity of the defect, which posed a significant challenge for reconstruction.

To address this complex scenario, the surgical team recommended a custom acetabular implant solution — specifically, a custom-designed FTL cup to restore stability and function in revision hip arthroplasty.

Surgical planning

In close collaboration with the surgeon, the Jajal Medical design team initiated a detailed preoperative planning process.

• Advanced CT imaging and 3D segmentation were used to precisely map the patient’s bone anatomy
• Based on the defect morphology, a patient-specific FTL cup was engineered to provide maximum coverage and optimal load distribution
• Virtual prototypes of the implant were shared with the surgeon for review, ensuring accuracy and clinical confidence before manufacturing

3D-printed, patient-specific implant

The implant was manufactured using state-of-the-art metal 3D printing technology with medical-grade titanium Ti6Al4V, offering superior strength, biocompatibility and long-term durability.

This custom acetabular implant provided a robust solution for a case where standard revision options were not viable.

• Custom geometry tailored to fit the patient’s acetabular defect
• Porous lattice structure at the bone-implant interface to promote long-term osseointegration
• Optimised screw trajectories for enhanced fixation in available host bone
• Dedicated drilling guides supplied to ensure accurate screw placement during surgery

Post-op outcome

The revision hip replacement surgery was completed. The custom FTL cup fit seamlessly into the reconstructed acetabulum, with accurate screw fixation achieved using the provided drilling guides.

Early postoperative assessments demonstrated stable fixation, restored hip biomechanics and improved functional outcomes.

Clinical impact

This case highlights the critical role of custom 3D-printed implants in revision hip arthroplasty, particularly in scenarios of massive bone loss where conventional solutions are inadequate.

By integrating advanced imaging, precise 3D design and additive manufacturing, Jajal Medical delivered a personalised implant that enabled the surgeon to reconstruct the patient’s acetabulum and restore mobility confidently.