Precision Reconstruction in Frontal Defect with Customized PMMA Cranial Implant

Patient overview

A 25-year-old male presented with a frontal defect and fractured bone pieces reconstructed in a previous surgery. The surgeon requested a customised cranial implant solution tailored to the patient’s unique anatomy to achieve a successful outcome.

Surgical planning

The surgical team meticulously planned the procedure by designing a customised PMMA (polymethylmethacrylate) cranial plate implant, crafted to reconstruct the skull’s frontal bone curvature accurately.

• Designing the plate in two parts for precise alignment with the bone structure
• Using 3D printing to create both a skull bone model and a customised PMMA implant, ensuring proper fitment and validating the design before surgery

3D-printed, patient-specific solution

The use of 3D printing allowed the surgical team to visualise and evaluate the frontal bone defect, confirm the implant’s fit and curvature to the patient’s anatomy, and manufacture a durable, biocompatible PMMA cranial plate ensuring stability and precision during surgery.

Post-op outcome

The surgery was highly successful: the cranial plates were fixed securely without any loosening during the procedure, and the patient demonstrated significant improvement in both functional and cosmetic aspects post-surgery.

The combination of advanced 3D planning and a customised implant underscored the critical role of innovative technology in achieving precise and safe outcomes.