Paediatric musculoskeletal (MSK) disorders often produce severe limb deformities, that may require surgical correction. This may be challenging, especially in case of multiplanar, multifocal and/or multilevel deformities. The increasing implementation of novel technologies, such as virtual surgical planning (VSP), computer aided surgical simulation (CASS) and 3D-printing is rapidly gaining traction for a range of surgical applications in paediatric orthopaedics, allowing for extreme personalization and accuracy of the correction, by also reducing operative times and complications. However, prompt availability and accessible costs of this technology remain a concern. Here, we report our experience using an in-hospital low-cost desk workstation for VSP and rapid prototyping in the field of paediatric orthopaedic surgery.

From April 2018 to September 2022 20 children presenting with congenital or post-traumatic deformities of the limbs requiring corrective osteotomies were included in the study. A conversion procedure was applied to transform the CT scan into a 3D model. The surgery was planned using the 3D generated model. The simulation consisted of a virtual process of correction of the alignment, rotation, lengthening of the bones and choosing the level, shape and direction of the osteotomies. We also simulated and calculated the size and position of hardware and customized massive allografts that were shaped in clean room at the hospital bone bank. Sterilizable 3D models and PSI were printed in high-temperature poly-lactic acid (HTPLA), using a low-cost 3D-printer.

Twenty-three operations in twenty patients were performed by using VSP and CASS. The sites of correction were: leg (9 cases) hip (5 cases) elbow/forearm (5 cases) foot (5 cases) The 3D printed sterilizable models were used in 21 cases while HTPLA-PSI were used in five cases. customized massive bone allografts were implanted in 4 cases. No complications related to the use of 3D printed models or cutting guides within the surgical field were observed. Post-operative good or excellent radiographic correction was achieved in 21 cases.

In conclusion, the application of VSP, CASS and 3D-printing technology can improve the surgical correction of complex limb deformities in children, helping the surgeon to identify the correct landmarks for the osteotomy, to achieve the desired degree of correction, accurately modelling and positioning hardware and bone grafts when required. The implementation of in-hospital low-cost desk workstations for VSP, CASS and 3D-Printing is an effective and cost-advantageous solution for facilitating the use of these technologies in daily clinical and surgical practice.

Introduction and Objective

Virtual Surgical Planning (VSP) is becoming an increasingly important means of improving skills acquisition, optimizing clinical outcomes, and promoting patient safety in orthopedics and traumatology. Pediatric Orthopedics (PO) often deals with the surgical treatment of congenital or acquired limbs and spine deformities during infancy. The objective is to restore function, improve aesthetics, and ensure proper residual growth of limbs and spine, using osteotomies, bone grafts, age-specific or custom-made hardware and implants.

Summary Statement

Pincer deformities are involved in the genesis of femoro-acetabular impingement (FAI). Radiographic patterns suggestive of pincer deformities are common among general population. Prevalence of the pincer deformities among general population may be overestimated if only plain radiographs are considered.

The use of monoblock tapered stems has shown very good results in hip revision surgery, particularly in case of severe proximal femur bone deficiency.

However a too valgus neck, a short offset, may result in a high risk of dislocation. In addiction monoblock stems make the control of limb length difficult, and potentially increase the risk of subsidence or intraoperative fracture. Different types of modular tapered stems with distal fixation have been developed to allow a more user-friendly restoration of limb-lenght discrepancy and an indipendent proximal control of offset and anti-retroversion.

We assessed 64 hip revisions performed on 63 patients (mean age 62 years). Indication for treatment was: aseptic loosening (42 cases) septic loosening (18 cases) and periprosthetic fracture (4 cases). According to Paprosky classification, femoral defects were staged as type I (2 cases), type II (20 cases), type IIIA (25 cases) and type IIIB (13 cases); periprosthetic fractures were all type B2 according to the Vancouver classification. In all cases we used a Restoration® Modular (Striker, Orthopaedics) cone-conical uncemented stem implanted by a lateral approach, with a trans-femoral osteotomy in 19 cases. A preventive cerclage cable was used in 10 patients in case of very thin cortex. We used the minimum size stem in most of the cases.

Mean follow-up was 20 months (range 6–36). Short-term complications included hip dislocation (1 case), recurrent infection (1 case), stem subsidence > 5 mm (1 case). Mean Harris Hip Score improved from 43 to 81.9 (t test p< 0.0005), while limb lenght discrepancy improved in 97% of cases with symmetry in 76%.

The use of modular revision stems is an effective alternative in hip revision surgery that ensures good primary stability, while modularity enables the implant to be tailored to the patient, allowing restoration of the limb length and correct muscular balancing.