The 3D printed titanium ribs were created by Australian state-owned Commonwealth Scientific and Industrial Research Organisation (CSIRO) 3D printing facility Lab 22, located in Melbourne, Australia.

The cancer patient had had a tumour in the chest wall, and surgeons had ruled reconstruction to be difficult due to the complex geometry of the chest cavity and that fact that conventional titanium implants were held together by screws, which over time could come undone and cause further complications.

As such, doctors considered designing a new type of implant that they could customise to replicate the intricate structures of the sternum and ribs, which would be a safer solution.

In today’s world, 3D technology is gaining rising interest and popularity in many sectors, including that of medical. In fact, some clinics and hospitals have been using 3D models for almost 10 years, as they offer better opportunities for surgeons to plan procedures and educate patients.

Creating and implanting a 3D-printed sternum and rib cage however is a first for the medical industry. Using 2D images from X-rays, computed tomography (CT) or magnetic resonance imaging (MRI), the resection margins to accommodate the chest wall and tumour were accurately defined.

Using an electron beam to melt titanium powder, a rigid sternal core and semi-flexible titanium robs were then created layer by layer to act as prosthetic ribs attached to the sternum.

According to Alex Kingsbury of CSIRO, 3D printing has significant advantages over traditional manufacturing methods, particularly for biomedical applications. “As well as being customisable, it also allows for rapid prototyping—which can make a big difference if the patient is waiting for surgery.”

The resultant sternum and rib cage, being fully customised, was a perfect fit to the patient’s body. The operation was hence a success.