Custom acetabular components have become an established method of treating massive acetabular bone defects in hip arthroplasty. Complication rates, however, remain high and migration of the cup is still reported. Ischial screw fixation (IF) has been demonstrated to improve mechanical stability for non-custom, revision arthroplasty cup fixation. We hypothesise that ischial fixation through the flange of a custom acetabular component aids in anti-rotational stability and prevention of cup migration. Electronic patient records were used to identify a consecutive series of 49 custom implants in 46 patients from 2016 to 2022 in a unit specializing in complex joint reconstruction. IF was defined as a minimum of one screw inserted into the ischium passing through a hole in a flange on the custom cup. The mean follow-up time was 30 months. IF was used in 36 cups. There was no IF in 13 cups. No difference was found between groups in age (68.9 vs. 66.3, P = 0.48), BMI (32.3 vs. 28.2, P = 0.11) or number of consecutively implanted cups (3.2 vs. 3.6, P = 0.43). Aseptic loosening with massive bone loss was the primary indication for revision. There existed no difference in Paprosky grade between the groups (P = 0.1). 14.2% of hips underwent revision and 22.4% had at least one dislocation event. No ischial fixation was associated with a higher risk of cup migration (6/13 vs. 2/36, X2 = 11.5, P = 0.0007). Cup migration was associated with an increased risk for all cause revision (4/8 vs. 3/38, X2 = 9.96, P = 0.0016, but not with dislocation (3/8 vs. 8/41, X2 = 1.2, P = 0.26). The results suggest that failure to achieve adequate ischial fixation, with screws passing through the flange of the custom component into the ischium, increases the risk of cup migration, which, in turn, is a risk factor for revision

We present the indications and outcomes of a series of custom 3D printed titanium acetabular implants used over a 9 year period at our institution (Sydney, Australia), in the setting of revision total hip arthroplasty. Individualised image-based case planning with additive manufacturing of pelvic components was combined with screw fixation and off-the-shelf femoral components to treat patients presenting with failed hip arthroplasty involving acetabular bone loss. Retrospective chart review was performed on the practices of three contributing surgeons, with an initial search by item number of the Medicare Benefits Scheme linked to a case list maintained by the manufacturer. An analysis of indications, patient demographics and clinical outcome was performed. The cohort comprised 65.2% female with a median age of 70 years (interquartile range 61–77) and a median follow up of 32.9 months (IQR 13.1 - 49.7). The indications for surgery were infection (12.5%); aseptic loosening (78.1%) and fracture (9.4%), with 65.7% of cases undergoing previous revision hip arthroplasty. A tumour prosthesis was implanted into the proximal femur in 21.9% of cases. Complications were observed in 31.3% of cases, with four cases requiring revision procedures and no deaths reported in this series. Kaplan-Meier analysis of all-cause revision revealed an overall procedure survival of 88.7% at two years (95%confidence interval 69 - 96.2) and 83.8% (95%CI 62 - 93.7) at five years, with pelvic implant-specific survival of 98% (95%CI 86.6 - 99.7) at two and five year follow up. We conclude that an individualised planning approach for custom 3D printed titanium acetabular implants can provide high overall and implant-specific survival at up to five years follow up in complex cases of failed hip arthroplasty and acetabular bone loss

Aims. Custom triflange acetabular components (CTACs) play an important role in reconstructive orthopaedic surgery, particularly in revision total hip arthroplasty (rTHA) and pelvic tumour resection procedures. Accurate CTAC positioning is essential to successful surgical outcomes. While prior studies have explored CTAC positioning in rTHA, research focusing on tumour cases and implant flange positioning precision remains limited. Additionally, the impact of intraoperative navigation on positioning accuracy warrants further investigation. This study assesses CTAC positioning accuracy in tumour resection and rTHA cases, focusing on the differences between preoperative planning and postoperative implant positions. Methods. A multicentre observational cohort study in Australia between February 2017 and March 2021 included consecutive patients undergoing acetabular reconstruction with CTACs in rTHA (Paprosky 3A/3B defects) or tumour resection (including Enneking P2 peri-acetabular area). Of 103 eligible patients (104 hips), 34 patients (35 hips) were analyzed. Results. CTAC positioning was generally accurate, with minor deviations in cup inclination (mean 2.7°; SD 2.84°), anteversion (mean 3.6°; SD 5.04°), and rotation (mean 2.1°; SD 2.47°). Deviation of the hip centre of rotation (COR) showed a mean vector length of 5.9 mm (SD 7.24). Flange positions showed small deviations, with the ischial flange exhibiting the largest deviation (mean vector length of 7.0 mm; SD 8.65). Overall, 83% of the implants were accurately positioned, with 17% exceeding malpositioning thresholds. CTACs used in tumour resections exhibited higher positioning accuracy than rTHA cases, with significant differences in inclination (1.5° for tumour vs 3.4° for rTHA) and rotation (1.3° for tumour vs 2.4° for rTHA). The use of intraoperative navigation appeared to enhance positioning accuracy, but this did not reach statistical significance. Conclusion. This study demonstrates favourable CTAC positioning accuracy, with potential for improved accuracy through intraoperative navigation. Further research is needed to understand the implications of positioning accuracy on implant performance and long-term survival. Cite this article: Bone Jt Open 2024;5(4):260–268

Complex acetabular reconstruction for oncology and bone loss are challenging for surgeons due to their often hostile biological and mechanical environments. Titrating concentrations of silver ions on implants and alternative modes of delivery allow surgeons to exploit anti-infective properties without compromising bone on growth and thus providing a long-term stable fixation. We present a case series of 12 custom acetabular tri-flange and custom hemipelvis reconstructions (Ossis, Christchurch, New Zealand), with an ultrathin plasma coating of silver particles embedded between layers of siloxane (BioGate HyProtect™, Nuremberg, Germany). At the time of reporting no implant has been revised and no patient has required a hospital admission or debridement for a deep surgical site infection. Routine follow up x-rays were reviewed and found 2 cases with loosening, both at their respective anterior fixation. Radiographs of both cases show remodelling at the ilium indicative of stable fixation posteriorly. Both patients remain asymptomatic. 3 patients were readmitted for dislocations, 1 of whom had 5 dislocations within 3 weeks post-operatively and was immobilised in an abduction brace to address a lack of muscle tone and has not had a revision of their components. Utilising navigation with meticulous implant design and construction; augmented with an ultrathin plasma coating of silver particles embedded between layers of siloxane with controlled and long-term generation of silver ion diffusion has led to outstanding outcomes in this series of 12 custom acetabular and hemipelvis reconstructions. No patients were revised for infection and no patients show signs of failure of bone on growth and incorporation. Hip instability remains a problem in these challenging mechanical environments and we continue to reassess our approach to this multifaceted problem

Abstract. Introduction. Patients presenting with loosening or a fracture between ipsilateral hip and knee replacements provide a unique reconstructive challenge. We present mid-term results of the cement-over megaprosthesis (COM) when managing these complex cases. A COM is cement-linked to the stem of a well-fixed existing implant. We report the largest series to date and show that this may be preferable to total femoral replacement in a cohort of patients who often have significant co-morbidities. Methodology. A retrospective analysis of patients undergoing COM between 2002–2022 was performed. Primary outcomes were defined as implant survival, displayed with survival analysis. Secondary outcomes included mortality and surgical complications. Functional outcomes included Visual Analogue Score (VAS), EuroQol-5D-3L and Musculoskeletal Tumour Society (MSTS) score at one year post operatively. Results. 34 patients underwent reconstructive cement-over technique. There were 20 custom distal femur replacements and 10 custom proximal femoral replacements. Two patients were revised, with a ten year implant survival of 94%. Fifteen patients died during the study period with an mean time to death of 66 months (25–109). The mean follow up was 75 months. 11 patients (32%) developed surgical complications. Mean VAS score was 4.9 (1–10), EuroQol-5D-3L index 0.45 (−0.59 – 0.88) and MSTS score was 16.8 (2–27) in 29 patients. Conclusion. The COM technique provides good implant survivorship in complex cases with compromised bone stock and this series confirms this as an established alternative to total femoral replacement in these cases

The purpose of this study is to report the clinical and radiological outcomes of patients undergoing primary or revision reverse total shoulder arthroplasty using custom 3D printed components to manage severe glenoid bone loss with a minimum of 2-year follow-up. After ethical approval (reference: 17/YH/0318), patients were identified and invited to participate in this observational study. Inclusion criteria included: 1) severe glenoid bone loss necessitating the need for custom implants; 2) patients with definitive glenoid and humeral components implanted more than 2 years prior; 3) ability to comply with patient reported outcome questionnaires. After seeking consent, included patients underwent clinical assessment utilising the Oxford Shoulder Score (OSS), Constant-Murley score, American Shoulder and Elbow Society Score (ASES), and quick Disabilities of the Arm, Shoulder, and Hand Score (quickDASH). Radiographic assessment included AP and axial projections. Patients were invited to attend a CT scan to confirm osseointegration. Statistical analysis utilised included descriptive statistics (mean and standard deviation) and paired t test for parametric data. 3 patients had revision surgery prior to the 2-year follow-up. Of these, 2/3 retained their custom glenoid components. 4 patients declined to participate. 5 patients were deceased at the time of commencement of the study. 21 patients were included in this analysis. The mean follow-up was 36.1 months from surgery (range 22–60.2 months). OSS improved from a mean 16 (SD 9.1) to 36 (SD 11.5) (p < 0.001). Constant-Murley score improved from mean 9 (SD 9.2) to 50 (SD 16.4) (p < 0.001). QuickDASH improved from mean 67 (SD 24) to 26 (SD 27.2) (p = 0.004). ASES improved from mean 28 (SD 24.8) to 70 (SD 23.9) (p = 0.007). Radiographic evaluation demonstrated good osseointegration in all 21 included patients. The utility of custom 3D-printed components for managing severe glenoid bone loss in primary and revision reverse total shoulder arthroplasty yields significant clinical improvements in this complex patient cohort

Osteosarcoma is a highly malignant primary tumor of bone tissue. The 5-year survival rate of patients with metastasis is below 20% and this scenario is unchanged in the last two decades, despite great efforts in pre-clinical and clinical research. Traditional preclinical models of osteosarcoma do not consider the whole complexity of its microenvironment, leading to poor correlation between in vitro/in vivo results and clinical outcomes. Spheroids are a promising in vitro model to mimic osteosarcoma and perform drug-screening tests, as they (i) reproduce the microarchitecture of the tumor, (ii) are characterized by hypoxic regions and necrotic core as the in vivo tumor, (iii) and recapitulate the chemo-resistance phenomena. However, to date, the spheroid model is scarcely used in osteosarcoma research. Our aim is to develop a customized culture dish to grow and characterize spheroids and to perform advanced drug-screening tests. The resulting platform must be adapted to automated image acquisition systems, to overcome the drawbacks of commercial spheroids platforms. To this purpose, we designed and developed a micro-patterned culture dish by casting agarose on a 3D printed mold from a CAD design. We successfully obtained viable and reproducible homotypic osteosarcoma spheroids, with two different cells lines from osteosarcoma (i.e., 143b and MG-63). Using the platform, we performed viability assays and live fluorescent stainings (e.g., Calcein AM) with low reagent consumption. Moreover, the culture dish was validated as drug screening platform, administrating Doxorubicin at different doses, and evaluating its effect on OS spheroids, in terms of morphology and viability. This platform can be considered an attractive alternative to the highly expensive commercial spheroid platforms to obtain homogeneous and reproducible spheroids in a high-throughput and cost effective mode

Proximal femoral focal deficiency is a congenital disorder of malformation of the proximal femur and/or the acetabulum. Patients present with limb length discrepancy and clinical features along a spectrum of severity. As these patients progress through to skeletal maturity and on to adulthood, altered biomechanical demands lead to progression of arthropathy in any joint within the lower limb. Abnormal anatomy presents a challenge to surgeons and conventional approaches and implants may not necessarily be applicable. We present a case of a 62-year-old lady with unilateral proximal femoral focal deficiency (suspected Aitken Class A) who ambulated with an equinus prosthesis for her entire life. She presented with ipsilateral knee pain and instability due to knee arthritis but could not tolerate a total knee arthroplasty due to poor quadriceps control. A custom osteointegration prosthesis was inserted with a view to converting to the proximal segment to a total hip replacement if required. The patient went on to develop ipsilateral symptomatic hip arthritis but altered acetabular anatomy required a custom tri-flange component (Ossis, Christchurch, New Zealand) and a custom proximal femoral component to link with the existing osseointegration component (Osseointegration Group of Australia, Sydney, Australia) were designed and implanted. The 18 month follow up of the custom hip components showed that the patient had Oxford hip scores that were markedly improved from pre-operatively. Knee joint heights were successfully restored to equal when the patient's prosthesis was attached. The patient describes feeling like “a normal person”, walks unaided for short distances and can ambulate longer distances with crutches. Advances in design and manufacture of implants have empowered surgeons to offer life improving treatments to patients with challenging anatomy. Using a custom acetabular tri-flange and osseointegration components is one possible solution to address symptomatic ipsilateral hip and knee arthropathy in the context of PFFD in adulthood

INTRODUCTION. Postoperative functional limitations after Total Knee Arthroplasty (TKA) are caused, in part, by a mismatch between a patient's natural anatomy and conventional “off-the-shelf” implants. To address this, we propose a new concept combining off-the-shelf femur and tibia implants with custom polyethylene tibial inserts designed to account for a patient's unique anatomy. Our goal in this study was to use knee specific computational modeling to determine the neutral path of motion and laxity of an intact knee under axial compression and shear forces through full flexion and compare intact motion against the same knee implanted with a conventional off-the-shelf vs. a custom tibial insert. METHODS. 3D models of a healthy knee joint were acquired from an open development repository funded by the National Institute of Biomedical Imagining and Bioengineering (Harris et al., 2016). The knee model was virtually implanted with conventional (off-the-shelf) posterior cruciate retaining (CR) components including the femoral component, tibial tray, and a conventional insert. A custom CR tibial insert was designed taking into account native articular geometry and compatibility with placement of the off-the-shelf femoral/tibial tray. Bone, cartilage and implant models were imported into ANSYS Workbench. Ligaments were calibrated using data from in-vitro experimental tests (Harris et al., 2016). The following load conditions were applied to the femur: 20 N axial compression (neutral path), 20 N axial compression with 80 N anterior shear force, and 20 N axial compression with 80 N posterior shear force. Simultaneously for each loading condition, the knee was flexed from 0 – 120 degrees. A circular axis system was used to describe the motion of the femur relative to the tibia. RESULTS. For the intact case, neutral path was characterized by greater posterior femoral displacement on the lateral side than on the medial side, especially in early flexion. Neutral path of the custom insert was closer to intact condition than the conventional insert. Overall AP laxity was similar between intact and implanted models except at 30 degrees where increased laxity occurred posteriorly for the implanted models, likely due to resection of the anterior cruciate ligament (ACL) as part of the TKA procedure. For intact and implanted models, AP laxity significantly decreased at the higher flexion angles. DISCUSSION. Our findings indicate that motion with a custom tibial insert was closer to intact than the conventional design. Nonetheless, custom articular surface alone may not fully reproduce intact motion due to limitations such as resection of the ACL, and such custom inserts may benefit from guiding features such as a cam, post, or retention of the native ACL to more closely reproduce normal knee function. We did not simulate specific activities of daily living. Increasing the magnitudes of compression and shear forces would not change the neutral path of motion, although, a reduction in laxity would be expected

Knee replacement is a proven and reproducible procedure to alleviate pain, re-establish alignment and restore function. However, the quality and completeness to which these goals are achieved is variable. The idea of restoring function by reproducing condylar anatomy and asymmetry has been gaining favor. As knee replacements have evolved, surgeons have created a set of principles for reconstruction, such as using the femoral transepicondylar axis (TEA) in order to place the joint line of the symmetric femoral component parallel to the TEA, and this has been shown to improve kinematics. However, this bony landmark is really a single plane surrogate for independent 3-dimensional medial and lateral femoral condylar geometry, and a difference has been shown to exist between the natural flexion-extension arc and the TEA. The TEA works well as a surrogate, but the idea of potentially replicating normal motion by reproducing the actual condylar geometry and its involved, individual asymmetry has great appeal. Great variability in knee anatomy can be found among various populations, sizes, and genders. Each implant company creates their specific condylar geometry, or “so called” J curves, based on a set of averages measured in a given population. These condylar geometries have traditionally been symmetric, with the individualised spatial placement of the (symmetric) curves achieved through femoral component sizing, angulation, and rotation performed at the time of surgery. There is an inherent compromise in trying to achieve accurate, individual medial and lateral condylar geometry reproduction, while also replicating size and avoiding component overhang with a set implant geometry and limited implant sizes. Even with patient-specific instrumentation using standard over-the-counter implants, the surgeon must input his/her desired endpoints for bone resection, femoral rotation, and sizing as guidelines for compromise. When all is done, and soft tissue imbalance exists, soft tissue release is the final, common compromise. The custom, individually made knee design goals include reproducible mechanical alignment, patient-specific fit and positioning, restoration of articular condylar geometry, and thereby, more normal kinematics. A CT scan allows capture of three-dimensional anatomical bony details of the knee. The individual J curves are first noted and corrected for deformity, after which they are anatomically reproduced using a Computer-Aided Design (CAD) file of the bones in order to maximally cover the bony surfaces and concomitantly avoid implant overhang. No options for modifications are offered to the surgeon, as the goal is anatomic restoration. Given these ideals, to what extent are patients improved? The concept of reproducing bony anatomy is based on the pretext that form will dictate function, such that normal-leaning anatomy will tend towards normal-leaning kinematics. Therefore, we seek to evaluate knee function based on objective assessments of movement or kinematics. In summary, the use of custom knee technology to more closely reproduce an individual patient's anatomy holds great promise in improving the quality and reproducibility of postoperative function. Compromises of fit and rotation are minimised, and implant overhang is potentially eliminated as a source of pain. Early results have shown objective improvements in clinical outcomes. Admittedly, this technology is limited to those patients with mild to moderate deformity at this time, since options like constraint and stems are not available. Yet these are the patients who can most clearly benefit from a higher functional state after reconstruction. Time will reveal if this potential can become a reproducible reality

The best treatment method of large acetabular bone defects at revision THR remains controversial. Some of the factors that need consideration are the amount of residual pelvic bone removed during revision; the contact area between the residual pelvic bone and the new implant; and the influence of the new acetabular construct on the centre of rotation of the hip. The purpose of this study was to compare these variables in two of the most used surgical techniques used to reconstruct severe acetabular defects: the trabecular metal acetabular revision system (TMARS) and a custom triflanged acetabular component (CTAC). Pre- and post-operative CT-scans were acquired from 11 patients who underwent revision THR with a TMARS construct for a Paprosky IIIB defect, 10 with pelvic discontinuity, at Royal Adelaide Hospital. The CT scans were used to generate computer models to virtually compare the TMARS and CTAC constructs using a semi-automated method. The TMARS construct model was calculated using postoperative CT scans while the CTAC constructs using the preoperative CT scans. The bone contact, centre of rotation, inclination, anteversion and reamed bone differences were calculated for both models. There was a significant difference in the mean amount of bone reamed for the TMARS reconstructions (15,997 mm. 3. ) compared to the CTAC reconstructions (2292 mm. 3. , p>0.01). There was no significant difference between overall implant bone contact (TMARS 5760mm. 2. vs CTAC 5447mm. 2. , p=0.63). However, there was a significant difference for both cancellous (TMARS 4966mm. 2. vs CTAC 2887mm. 2. , p=0.008) and cortical bone contact (TMARS 795mm. 2. vs CTAC 2560mm. 2. , p=0.001). There was no difference in inclination and anteversion achieved. TMARS constructs resulted on average in a centre of rotations 7.4mm more lateral and 4.0mm more posterior. Modelling of two different reconstructions of Paprosky IIIB defects demonstrated potential important differences between all variables investigated

The custom triflange acetabular component has been advocated for severe acetabular defects and pelvic discontinuity, cases in which a porous-coated hemisphere will not work. These are AAOS type III or IV defects, or alternatively classified as Paprosky 3B. Many have a pelvic discontinuity. A pre-operative CT of the pelvis is sent to the manufacturer who generates a one-to-one scale 3D model of the hemipelvis. The surgeon can review either a pdf file or an actual model. If the visualised defect cannot be treated with traditional methods then a triflanged component is created. The components have backside porous and hydroxyapatite coating. Initial rigid fixation is obtained with screw fixation to the ilium and ischium. Subsequent bone ingrowth can provide long term fixation. The goal is to span the acetabular defect and obtain fixation to the ilium and ischium with a third arm which rests on the pubis. Christie first reported on 67 hips (half with a discontinuity) with a mean follow-up of 53 months. No components were removed. There was an 8% reoperation for dislocation, 6% partial sciatic nerve palsy. 46% walked without support. Dennis reported 26 hips with a mean 54 month follow-up. Eighty-eight percent were considered successful. One implant was removed and left with a resection arthroplasty and 2 others had loose components but refused reoperation. Loosening of the ischial screws was a sign of failure in the three cases. Taunton reported 57 cases with a pelvic discontinuity treated with a triflange at mean follow-up of 65 months. Eighty-one percent had a stable component and a healed pelvic discontinuity. These authors also compared a custom triflange to a trabecular metal cup-cage construct finding similar implant costs of $12,500 and $11,250, respectively. All advocates of custom triflange acetabular components believe the results are similar or superior to other options in these very challenging cases at early follow-up. The primary disadvantage of the technique is the pre-operative time required to manufacture the device – typically 4–8 weeks

The custom triflange acetabular component has been advocated for severe acetabular defects and pelvic discontinuity, cases in which a porous-coated hemisphere will not work. These are AAOS type III or IV defects, or alternatively classified as Paprosky 3B. Many have a pelvic discontinuity. A preoperative CT of the pelvis is sent to the manufacturer who generates a one-to-one scale 3D model of the hemipelvis. The surgeon can review either a pdf file or an actual model. If the visualised defect cannot be treated with traditional methods then a triflanged component is created. The components have backside porous and hydroxyapatite coating. Initial rigid fixation is obtained with screw fixation to the ilium and ischium. Subsequent bone ingrowth can provide long term fixation. The goal is to span the acetabular defect and obtain fixation to ilium and ischium with a third arm which rests on the pubis. Christie first reported on 67 hips (half with a discontinuity) with a mean follow-up of 53 months. No components were removed. There was an 8% reoperation for dislocation, 6% partial sciatic nerve palsy. 46% walked without support. Dennis reported 26 hips with a mean 54 month follow-up. 88% were considered successful. One implant was removed and left with a resection arthroplasty and 2 others had loose components but refused reoperation. Loosening of the ischial screws was a sign of failure in the three cases. Taunton reported 57 cases with a pelvic discontinuity treated with a triflange at mean follow-up of 65 months. 81% has a stable component and a healed pelvic discontinuity. These authors also compared a custom triflange to a trabecular metal cup-cage construct finding similar implant costs of $12,500 and $11,250, respectively. All advocates of custom triflange acetabular components believe the results are similar or superior to other options in these very challenging cases at early follow-up. The primary disadvantage of the technique is the preoperative time required to manufacture the device – typically 4–8 weeks

18 years ago laboratory studies were started to develop a CT-based uncemented customised femoral stem in order to optimise the fixation and strain distribution to the proximal femur in uncemented femoral components. An individual design also aimed to optimise the biomechanics of the joint and to enable use of uncemented stems in femurs with abnormal shape and dimension. The developed prosthesis has now been in clinical use for 13 years. The aim of this paper is to present the preliminary results of a prospective clinical study of this prosthesis. Patients and methods: 685 hips have been operated. 58.8 % of the patients were women. Mean age was 51 years (20–69). 42.3 % of the hips were dysplastic. A high number of hips without major anatomic abnormality of the upper femur were included. The prostheses were designed to obtain a neck anteversion of 10 degrees after insertion, optimised medial femoral head offset and correction of leg length discrepancies up to 3 cm. All patients were followed with radiological and clinical examination. Merle d’Aubigné score was used. RSA and DEXA-studies have been performed in some groups of the patients. Finally, study of the gluteal muscular function in hips with optimised medial femoral head offset after insertion of custom stems was compared to hips where optimisation had not been achieved with use of standard stems. Results: We experienced that use of this type of prosthesis is very simple and offers obvious advantages in abnormal size and geometry of the upper femur. Nine patients sustained a peroperative fissure in the proximal femur (1.3 %). These fissures were treated successfully with cerclage wires. Eight patients sustained a femoral fracture by a fall accident. Four fractures healed after osteosynthesis without loosening of the prosthesis. A long stem pros-thesis had to be used in the other four. No stem loosening was seen except in one case where a non-union after subtrochanteric osteotomy prevented stem fixation. Dislocation occurred in ten hips (1.5%). In four of these the acetabular component had to be replaced. Average total score at 7 years (125 hips) was 17.1 (preop 9.4), at 10 years (56 hips) 17.0 (preop 9.4). The pain scores at the corresponding observations were 5.7 (preop 2.7) and 5.6 (preop 2.8). DEXA-studies showed comparable preservation of femoral bone stock in hips treated with custom and standard stems (ABG). RSA-studies showed no significant stem migration. Superior function of the gluteal muscles was obtained after normalisation of the medial femoral head offset after insertion of a custom stem when compared to hips where normalisation had not been achieved by a standard stem. Conclusions: Use of custom femoral components enables optimisation of the biomechanics of the hip and eliminates the need for highly modular femoral stems. The rate of peroperative fissures and postoperative instability is relatively low indicating adequate fit of the stem and adequate design of the femoral neck. Use of custom prostheses offers obvious advantages in highly abnormal femurs. The mid-term clinical results up to 10 years are promising with a very low risk of aseptic loosening. However, it remains to see whether use of such pros-theses will give superior long term results compared to standard uncemented stems in “normal” femurs

Recently, a new technique of custom-made cutting guides for TKA is introduced to clinical practice. However, no published data yet on the comparison between this new technique against both navigation and conventional techniques. The author prospectively compared between custom-made cutting guides, navigation and conventional techniques. A total number of 90 cases were included in this study with 30 consecutive cases for each technique. The highest number of medically unfit patients and those with articular and extra articular deformities were in custom guides groups. The results showed one case of aseptic loosening after one year in custom guides, one case of superficial infection and loose pins but with no fracture in navigation group, and higher need for blood transfusion in conventional. One case in the custom guide group had a periprosthetic fracture 3 weeks postoperatively diagnosed as insufficiency fracture after a relatively minor trauma to an osteoporotic bone. Navigation was the most accurate in alignment but custom guides was the most accurate in implant sizing and had the least bleeding. This clinical study showed some advantages of custom-made cutting guides over conventional instrumentation. It eliminated medullary guides, reduced operative time, and provided better accuracy. The technique was proved to be useful in complex cases of deformities and unfit patients

Advantages of custom made prosthesis are the 3D-Planing and correction of the head position using the best possible form fit. Considering these properties we examined several off the shelf systems if they can fulfil the requirements to form fit and head position. By using our fit program we simulated the implantation of five different off the shelf systems in more than 200 individual reconstructed femora. The data of these bones were used for constructing a custom made implant, so the best form fit and head position could be compared with the result of the fit. All of the patients were younger than 65 years. The data of the off the shelf prostheses systems came from 3D measurement. All systems were described as anatomical. The fit program is an optimization program which can implant a 3D prosthesis model in a reconstructed 3D femur by variation of all six special parameters simultaneously. Compared to the demands of our custom implants, the results of the virtual implantation of the off the shelf systems, are more or less unsatisfactory. Depending on the acceptable tolerance of the limits in offset, leg lengthening and anteversion up to 50% of the patients could not be treated with a single off the shelf system, when the best form fit was reached sufficiently. Using the results of this examination we enlarged our custom-made prosthesis system with six different sizes of an anatomical like off the shelf prostheses. By perfoming the same fit simulation with our new implants we found that more than 70% of our patients could be treated with this implant sufficiently, when using the same limits. A good correspondence was found between the computer fit, which was calculated in advance, and the postoperative situation. The combined system of custom and off the shelf prostheses in addition with our 3D planning system based on CT examination, leads to new way of choosing the best implant for a single patient. If the virtual implantation of an off the shelf system does not give a satisfying result, the custom-made CTX prosthesis will be chosen for this patient

Hypothesis. Custom cutting blocks can produce similar alignment compared to computer navigated and conventional total knee arthroplasty (TKA) techniques. Method. We conducted a retrospective review of 37 patients who underwent TKA by a single surgeon in a teaching hospital setting. Groups were conventional method (10), computer assisted navigation (10), and custom blocks (18). The custom group was further subdivided to CT and MRI based blocks. Post-operative alignment was measured (blinded) using full length weight bearing radiographs at 18 weeks on average. Hospital records were reviewed to determine operative time, transfusion requirements, length of hospital stay, complications and cost. Results. Post-operative mechanical axis was within 3 degrees of neutral in 100% of the navigation group, 70% of the conventional group and 50% of the custom block group. Average alignment was within 1.8, 3.1 and 3.6 degrees of neutral for each group respectively. The operative time was greater for the computer navigation group (86.7 min) compared to the conventional (72.1) and MRI custom block groups which involved unfamiliar instrumentation (73.8). CT based block procedures involved otherwise familiar instruments and averaged 61.2 minutes. Length of hospital stay and complications were similar for all three groups. Total cost was the least for the conventional group. Increased costs were associated with computer equipment, pre-operative advanced imaging and custom blocks. Conclusions. Custom cutting blocks in this small series obtain worse radiographic positioning of total knee arthroplasty components compared to conventional and computer navigation techniques. Further studies with greater number of patients, CT alignment analysis and long-term follow-up are required

Introduction. Custom instrumentation in TKA utilizes pre-operative imaging to generate a customized guide for cutting block placement (Figure 1). The surgeon is able to modify the plan using three-dimensional software (Figure 2). Although this technology is increasingly gaining acceptance, there is a paucity of clinical data supporting it. Methods. One hundred and eleven patients underwent primary TKA using the Patient-Specific Instrumentation (PSI) system, in twenty-eight of the cases surgical navigation was used to validate the PSI-generated cuts. Alignment measurements included long-leg alignment and biplanar distal femoral and proximal tibial cuts. Further measurements evaluated femoral implant placement in the AP plane, femoral component rotation, measured bone resection and implant sizing accuracy. Results. The mean final limb alignment as recorded by computer-assisted surgical (CAS) tools was 0.3° of varus. Only two limbs were malaligned by greater than 3° (Figure 3). The femoral component had a mean alignment of 0.3° of valgus and 4.5° of flexion (PSI plan 3° flexion). The predicted femoral size was accurate in 89% of cases and the anterior femoral cut was congruent with the anterior cortex in 92% of cases. The PSI-directed femoral component rotation was consistent with the surgeon's perceived rotation in 95% of cases. The posterior condylar bone resection had a mean difference of < 1mm from the predicted resection. The tibial component had a mean alignment of 0.5° of varus and 8.5° of posterior slope (PSI plan 7° posterior slope). The only statistically significant deviation in alignment was the increased tibial slope (p=0.046) (Figure4). The tibial component size was accurately predicted in 66% of cases. Discussion. Custom instrumentation in total knee arthroplasty accurately achieved implant and limb alignment in our study. The plan was more reproducible on the femoral slide. The overestimation of tibial slope and tibial sizing incongruity were related to some of the reference points for the software. A potential benefit of this technology is improved mid-flexion stability by accurately determining femoral component size, placement, and rotation. Further studies are needed to determine the efficiency and cost-effectiveness of this technology

Aim. The aim of this study is to outline the steps and techniques required to create a patient specific 3D printed guide for the accurate placement of the origin of the femoral tunnel for single bundle ACL reconstruction. Introduction. Placements of the femoral tunnels for ACL reconstruction have changed over the years. Most recently there has been a trend towards placing the tunnels in a more anatomic position. There has been subsequent debate as to where this anatomic position should be. The problem with any attempt at consensus over the placement of an anatomic landmark is that each patient has some variation in their positioning and therefore a fixed point for all has compromise for all as it is an average. Our aim was to attempt to make a cost effective and quick custom guide that could allow placement of the center of the patients’ newly created femoral tunnel in the mid position of their contralateral native ACL femoral footprint. Materials & Methods. We took a standard protocol MRI scan of a patient's knee without ACL injury transferred the DICOM files to a personal computer running OsiriX (Pixmeo, Geneva, Switzerland.) and analysed it for a series of specific anatomical landmarks. OsiriX is an image processing software dedicated to DICOM images. We marked the most posterior edge of the articular cartilage on the lateral wall of the notch (1), the most anterior edge of the articular cartilage of the lateral wall of the notch (2), the most inferior edge of the articular cartilage of the lateral wall of the notch (3) and the center of the femoral footprint of the native ACL. Distances were then calculated to determine the position relative to the three articular cartilage points of the center of the ACL footprint. These measurements and points were then utilised to create a 3D computer aided design (CAD) model of a custom guide. This was done using the 3D CAD program 123Design (Autodesk Ltd., Farnbourgh, Hampshire). This 3D model was then exported as an STL file suitable for 3D printing. The STL file was then uploaded to an online 3D printing service and the physical guide was created in transparent acrylic based photopolymer, PA220 plastic and 316L stainless steel. The models created were then measured using vernier calipers to confirm the accuracy of the final guides. Results. The MRI data showed point 1 (AP), point 2 (distal-ACL), point 3 (Ant-ACL) and point 4 (Post-ACL) at a distance of 59.83, 15, 45.8 and 13.9 respectively. For the 3D CAD model, points 1, 2, 3 and 4 were at a distance of 59.83, 15, 45.8 and 13.9 respectively. For the PA220 plastic model, points 1, 2, 3 and 4 were at a distance of 59.86, 14.48, 45.85 and 13.79 respectively. For the 316L stainless steel model, points 1, 2, 3 and 4 were at a distance of 59.79, 14.67, 45.64 and 13.48 respectively. Lastly, for the photopolymer model, points 1, 2, 3 and 4 were at a distance of 59.86, 14.2, 45.4 and 13.69 respectively. The p-value comparing MRI/CAD vs. PA220 was p=0.3753; for the comparison between MRI/CAD vs. 316L, p=0.0683; lastly for the comparison between MRI/CAD Vs. Photopolymer, p=0.3450. The models produced were accurate with no statistical difference in size and positioning of the center of the ACL footprint from the original computer model and to the position of the ACL from the MRI scans. The costs for the models 3D printed were £3.50 for the PA220 plastic, £15 for the transparent photopolymer and £25 for the 316L stainless steel. The time taken from MRI to delivery for the physical models was 7 days. Discussion. Articles regarding the creation of 3D printed custom ACL guides from the patients contralateral knee do not feature in current literature. There has been much research on custom guides for other orthopaedic procedures such as in total knee arthroplasty for the accurate placement of implants. There has also been research published on the creation of custom cutting jigs from CT for complex corrective osteotomy surgery. This study serves as the first step and a proof of concept for the accurate creation of patient specific 3D printed guides for the anatomical placement of the femoral tunnel for ACL reconstruction. The guides were easy to create and produce taking only a week and with a cost of between £3.50 and £25. The design of the guides was to allow the tip of a standard Chondro Pick (Arthrex inc., Naples, Florida.) (3mm) used to mark the starting point of the femoral tunnel to enter through the guide. The next step for this research is to create guides from cadaveric matched knees and utilise the guides to carry out the creation of the femoral tunnels and to analyse of the placement of the tunnel in relation to the contralateral knee

Introduction: This report details the author’s experience with custom femoral implants for femoral replacement in total hip arthroplasty from 1988. The concepts, technology and results help define the role custom implants may play for present day arthroplasty. Methods: Custom femoral components were used in 48 patients, (22 female, 26 male). There were 52 primary THAs and 6 revision THAs. Initial diagnoses included osteoarthritis, developmental dysplasia, and osteonecrosis. The average patient age at surgery was 48.3 years. Clinical and radiographic results were by standard methodologies. Results: Mean follow-up was 119 months. These 3 stem variations were used – TiAlVa alloy stem with anterior, posterior and medial porous mesh pads (Ti-Mesh, Tech-medica), the same design with circumferential HA coating (TI-HA, Techmedica), and a TiAlVa alloy stem with circumferential plasma sprayed Ti with HA (PSHA, Biomet). A variety of acetabular components were used. Harris Hip Scores averaged 65 points pre-operatively and 83 at most recent follow-up. Forty stems (69%) showed hypertrophic cortical remodeling in more than two zones all with bone ingrowth. Eight stems (14%) showed osteolysis around the stem – all of the Ti-Mesh design. Eight cups showed loosening, 2 showed osteolysis, and 23 (39.7%) showed radiographic evidence for wear. Eight hips were revised: three for osteolysis; 4 stems for loosening; and one stem revision for recurrent dislocation (5 hip stems revised). All revised stems were of the Ti-Mesh design. There have been no failures of the HA coated implants at this time. Discussion: The results of this study suggest that fit and fill alone are not sufficient to provide durable fixation for uncemented THA. The use of circumferential coating substantially improved the performance of these devices. The technology associated with these devices is now available for use in complex revision arthroplasty, where customized approaches will find a permanent role