Aims. Proper preoperative planning benefits fracture reduction, fixation, and stability in tibial plateau fracture surgery. We developed and clinically implemented a novel workflow for 3D surgical planning including patient-specific drilling guides in tibial plateau fracture surgery. Methods. A prospective feasibility study was performed in which consecutive tibial plateau fracture patients were treated with 3D surgical planning, including patient-specific drilling guides applied to standard off-the-shelf plates. A postoperative CT scan was obtained to assess whether the screw directions, screw lengths, and plate position were performed according the preoperative planning. Quality of the fracture reduction was assessed by measuring residual intra-articular incongruence (maximum gap and step-off) and compared to a historical matched control group. Results. A total of 15 patients were treated with 3D surgical planning in which 83 screws were placed by using drilling guides. The median deviation of the achieved screw trajectory from the planned trajectory was 3.4° (interquartile range (IQR) 2.5 to 5.4) and the difference in entry points (i.e. plate position) was 3.0 mm (IQR 2.0 to 5.5) compared to the 3D preoperative planning. The length of 72 screws (86.7%) were according to the planning. Compared to the historical cohort, 3D-guided surgery showed an improved surgical reduction in terms of median gap (3.1 vs 4.7 mm; p = 0.126) and step-off (2.9 vs 4.0 mm; p = 0.026). Conclusion. The use of 3D surgical planning including drilling guides was feasible, and facilitated accurate screw directions, screw lengths, and plate positioning. Moreover, the personalized approach improved fracture reduction as compared to a historical cohort. Cite this article: Bone Jt Open 2024;5(1):46–52

Aims. Morphological abnormalities are present in patients with developmental dysplasia of the hip (DDH). We studied and compared the pelvic anatomy and morphology between the affected hemipelvis with the unaffected side in patients with unilateral Crowe type IV DDH using 3D imaging and analysis. Methods. A total of 20 patients with unilateral Crowe-IV DDH were included in the study. The contralateral side was considered normal in all patients. A coordinate system based on the sacral base (SB) in a reconstructed pelvic model was established. The pelvic orientations (tilt, rotation, and obliquity) of the affected side were assessed by establishing a virtual anterior pelvic plane (APP). The bilateral coordinates of the anterior superior iliac spine (ASIS) and the centres of hip rotation were established, and parameters concerning size and volume were compared for both sides of the pelvis. Results. The ASIS on the dislocated side was located inferiorly and anteriorly compared to the healthy side (coordinates on the y-axis and z-axis; p = 0.001; p = 0.031). The centre of hip rotation on the dislocated side was located inferiorly and medially compared to the healthy side (coordinates on the x-axis and the y-axis; p < 0.001; p = 0.003). The affected hemipelvis tilted anteriorly in the sagittal plane (mean 8.05° (SD 3.57°)), anteriorly rotated in the transverse plane (mean 3.31° (SD 1.41°)), and tilted obliquely and caudally in the coronal plane (mean 2.04° (SD 0.81°)) relative to the healthy hemipelvis. The affected hemipelvis was significantly smaller in the length, width, height, and volume than the healthy counterpart. (p = 0.014; p = 0.009; p = 0.035; p = 0.002). Conclusion. Asymmetric abnormalities were identified on the affected hemipelvis in patients with the unilateral Crowe-IV DDH using 3D imaging techniques. Improved understanding of the morphological changes may influence the positioning of the acetabular component at THA. Acetabular component malpositioning errors caused by anterior tilt of the affected hemi pelvis and the abnormal position of the affected side centre of rotation should be considered by orthopaedic surgeons when undertaking THA in patients with Crowe-IV DDH. Cite this article: Bone Joint J 2020;102-B(10):1311–1318

Introduction. The objective of this study is to assess the use of ultrasound (US) as a radiation free imaging modality to reconstruct three-dimensional knee anatomy. Methods. An OEM US system is fitted with an electromagnetic (EM) tracker that is integrated into the US probe, allowing for 3D tracking of probe and femur and tibia. The raw US RF signals are acquired and using real time signal processing, bone boundaries are extracted. Bone boundaries are then combined with the EM sensor information in a 3D point cloud for both femur and tibia. Using a statistical shape model, the patient specific surface is reconstructed by optimizing bone geometry to match the point clouds. An accuracy analysis was then conducted for 11 cadavers by comparing the 3D US models to those created using CT scans. Results. The results revealed the US bone models were accurate compared to the CT models (Mean RMS: femur: 1.03±0.15 mm, tibia:1.11± 0.13). Also, femoral landmarking proved to be accurate (transepicondylar axis: 1.07±0.65°, Posterior condylar axis: 0.73±0.41° Distal condylar axis: 1.12±0.89°, Medial AP: 1.39±1.18 mm, Lateral AP: 1.56±1.15 mm, TEA width: 1.2±0.87 mm). Tibial landmarking errors were slightly higher (Posterior slope axis: 2 ±1.19° and Tubercle axis: 1.8±1.37°). The models were then used to evaluate implant sizing as, 90% of the femurs and 60% of the tibias were sized correctly, while the others were off only one size. Discussion. The 3D US bone models were proven to be accurate compared to CT and can be used for preoperative planning. 3D ultrasound is radiation free and offers numerous clinical opportunities for bone creation in minutes during their office visit, surgeon-patient pre-operative planning, implant sizing and selection, 3D dynamic ligament balancing and intra-operative registration for use with robots and navigation systems

A complete design-manufacturing process for delivering customized foot orthoses by means of digital technologies is presented. Moreover, this feasibility study aims to combine a semi-automatic modelling approach with the use of low-cost devices for 3D scanning and 3D printing. In clinical practice, traditional methods for manufacturing customized foot orthoses are completely manual, mainly based on plaster casting plus hand fabrication, and are widely used among practitioners. Therefore, results depend on skills and expertise of individual orthoptists and podiatrists that need considerable training and practice in order to obtain optimal functional devices. On the other side, novel approaches for design and manufacturing customized foot orthoses by means of digital technologies (generally based on 3D scanning, 3D modelling and 3D printing) are recently reported as a valid alternative method to overcome these limitations. This study has been carried out in an interdisciplinary approach between the staff of Design and Methods in Industrial Engineering and the staff of Podology with the aim to assess the feasibility of a novel user-friendly and cost-effective solution for delivering customized functional foot orthoses. More specifically, a Generative Design (GD) workflow has been developed to enable practitioners without enough CAD skills to easily 3D modelling and interactively customize foot orthoses. Additionally, low-cost devices for 3D scanning and 3D printing that have been acquired by the Podology Lab, were also tested and compared with the high-cost ones of the Department of Industrial Engineering. The complete process is divided into three main steps. The first one regards the digitization of the patient's foot by means of 3D laser scanner devices. Then a user-friendly 3D modelling approach, developed for this purpose as GD workflow, allows interactively generating the customized foot orthosis, also adjusting several features and exporting the watertight mesh in STL format. Finally, the last step involves Additive Manufacturing systems to obtain the expected physical item ready to use. First, for what concerns the digitizing step, the acquired data resulting from 3D scanning by means of the low-cost system (Sense 3D scanner) appears accurate enough for the present practical purposes. Then, with respect to the 3D modelling step, the proposed GD workflow in Grasshopper is intuitive and allows easily and interactively customizing the final foot orthosis. Finally, regarding the Additive Manufacturing step, the low cost 3D printer (Wasp Delta 40 70) is capable to provide adequate results for the shell of the foot orthosis. Moreover, this system appears really versatile in reason of the capability to print in a wide range of different filaments. Therefore, since the market of 3D printing filaments is rapidly growing, building sessions with different materials (both flexible and rigid such, for example, PLA, AB and PETG) were completed. This study validated, in terms of feasibility, that the use of a GD modelling approach, in combination with low-cost devices for 3D scanning and 3D printing, is a real alternative to conventional processes for providing customized foot orthosis. Moreover, the interdisciplinary approach allowed the transfer of skills and knowledge to the practitioners involved and, also, the low-cost devices Sense 3D scanner and Wasp Delta 40 70 that have been acquired by the Podology Lab, were demonstrated suitable for this kind of applications

Aims. The aim of this study was to establish a reliable method for producing 3D reconstruction of sonographic callus. Methods. A cohort of ten closed tibial shaft fractures managed with intramedullary nailing underwent ultrasound scanning at two, six, and 12 weeks post-surgery. Ultrasound capture was performed using infrared tracking technology to map each image to a 3D lattice. Using echo intensity, semi-automated mapping was performed to produce an anatomical 3D representation of the fracture site. Two reviewers independently performed 3D reconstructions and kappa coefficient was used to determine agreement. A further validation study was undertaken with ten reviewers to estimate the clinical application of this imaging technique using the intraclass correlation coefficient (ICC). Results. Nine of the ten patients achieved union at six months. At six weeks, seven patients had bridging callus of ≥ one cortex on the 3D reconstruction and when present all achieved union. Compared to six-week radiographs, no bridging callus was present in any patient. Of the three patients lacking sonographic bridging callus, one went onto a nonunion (77.8% sensitive and 100% specific to predict union). At 12 weeks, nine patients had bridging callus at ≥ one cortex on 3D reconstruction (100%-sensitive and 100%-specific to predict union). Presence of sonographic bridging callus on 3D reconstruction demonstrated excellent reviewer agreement on ICC at 0.87 (95% confidence interval 0.74 to 0.96). Conclusion. 3D fracture reconstruction can be created using multiple ultrasound images in order to evaluate the presence of bridging callus. This imaging modality has the potential to enhance the usability and accuracy of identification of early fracture healing. Cite this article: Bone Joint Res 2021;10(12):759–766

Introduction: Degenerative osteoarticular conditions of the lower limb comprise of the most common orthopedic diseases requiring implants surgery. Biomechanical factors have an important role in the development of the degenerative process. Radiological diagnostics prominently rely on bidirectional 2D X-ray images, CT and MRI also being employed in the assessment process. However, these diagnostic tools usually cover a single joint, mostly unilaterally, rarely if ever providing a chance to simultaneously examine each members of the closed kinetic chain of both limbs under normal postural loads in a standing position. Classification and measurements of anatomical conditions are carried out in a 2D environment only and measured values are projected to real-life circumstances. EOS, a new 2D/3D digital imaging system based on Nobel-prize winning ultra low-dose X-ray radiation detection and a unique 3D toolbox with 3D reconstruction module offers a truly groundbreaking option in this field. We present results obtained during the first year of clinical use of our EOS 2D/3D system. Methods: 20 patients with coxarthrosis and 20 patients with gonarthrosis have been examined with traditional 2D X-ray and EOS 2D/3D system. Clinical parameters (femoral and tibial length, mechanical angle of the femur and tibia, anatomical and mechanical femorotibial angle, etc.) have been determined for both diagnostic methods and results were compared. 3D measurements available within EOS 3D toolbox were determined including femoral and tibial torsion and femorotibial rotation. For visualization of the lower limbs EOS 3D reconstructions were made. Results: Using EOS built-in 3D toolbox, comparison of numerical data for 2D and 3D measurements of clinical parameters showed a significant difference whereby 3D measurements always represented more valid, more accurate values. Differences between 2D and 3D measurement values were as much as 5–10 mm in length or 5–8 degrees in angles. This was particularly true for conditions where torsion and rotation of the bones were present. EOS 3D reconstruction module provided a surface reconstructed 3D model of the examined limbs and automatically displayed every clinically relevant parameters measured in the 3D toolbox. This proved to be an important feature for pre-operative planning and postoperative evaluations. Conclusion: EOS 2D/3D system provides a ground-breaking new tool for length and angle measurements of the lower limb in 3D, providing distortion-free clinical parameters that are accurate and true-to-life values, avoiding artefactual effects from projection, torsion and rotation and positioning of the patient, which usually concomitantly affect the accuracy and reproducibility of conventional 2D measurements

Aims. Computer-assisted 3D preoperative planning software has the potential to improve postoperative stability in total hip arthroplasty (THA). Commonly, preoperative protocols simulate two functional positions (standing and relaxed sitting) but do not consider other common positions that may increase postoperative impingement and possible dislocation. This study investigates the feasibility of simulating commonly encountered positions, and positions with an increased risk of impingement, to lower postoperative impingement risk in a CT-based 3D model. Methods. A robotic arm-assisted arthroplasty planning platform was used to investigate 11 patient positions. Data from 43 primary THAs were used for simulation. Sacral slope was retrieved from patient preoperative imaging, while angles of hip flexion/extension, hip external/internal rotation, and hip abduction/adduction for tested positions were derived from literature or estimated with a biomechanical model. The hip was placed in the described positions, and if impingement was detected by the software, inspection of the impingement type was performed. Results. In flexion, an overall impingement rate of 2.3% was detected for flexed-seated, squatting, forward-bending, and criss-cross-sitting positions, and 4.7% for the ankle-over-knee position. In extension, most hips (60.5%) were found to impinge at or prior to 50° of external rotation (pivoting). Many of these impingement events were due to a prominent ischium. The mean maximum external rotation prior to impingement was 45.9° (15° to 80°) and 57.9° (20° to 90°) prior to prosthetic impingement. No impingement was found in standing, sitting, crossing ankles, seiza, and downward dog. Conclusion. This study demonstrated that positions of daily living tested in a CT-based 3D model show high rates of impingement. Simulating additional positions through 3D modelling is a low-cost method of potentially improving outcomes without compromising patient safety. By incorporating CT-based 3D modelling of positions of daily living into routine preoperative protocols for THA, there is the potential to lower the risk of postoperative impingement events. Cite this article: Bone Jt Open 2023;4(6):416–423

In the last years, 3d printing has progressively grown and it has reached a solid role in clinical practice. The main applications brought by 3d printing in orthopedic surgery are: preoperative planning, custom-made surgical guides, custom-made im- plants, surgical simulation, and bioprinting. The replica of the patient's anatomy, starting from the elaboration of medical volumetric images (CT, MRI, etc.), allows a progressive extremization of treatment personalization that could be tailored for every single patient. In complex cases, the generation of a 3d model of the patient's anatomy allows the surgeons to better understand the case — they can almost “touch the anatomy” —, to perform a more ac- curate preoperative planning and, in some cases, to perform device positioning before going to the surgical room (i.e. joint arthroplasty). 3d printing is also commonly used to produce surgical cutting guides, these guides are positioned intraoperatively on given landmarks to guide the surgeon to perform a specific surgical act (bone osteotomy, bone resection, implant position, etc.). In total knee arthroplasty, custom-made cutting guides have been developed to help the surgeon align the femoral and tibial components to the pre-arthritic condition with- out the use of the intramedullary femoral guide. 3d printed custom-made implants represent an emerging alternative to biological reconstructions especially after oncologic resection surgery or in case of complex arthroplasty revision surgery. Custom-made implants are designed to re- place the original shape and size of the patient's bone and they allow an extreme personalization of the treatment for every single patient. Patient-specific surgical simulation is a new frontier that promises great benefits for surgical training. a solid 3d model of the patient's anatomy can faithfully reproduce the surgical complexity of the patient and it allows to generate surgical simulators with increasing difficulty to adapt the difficulties of the course with the level of the trainees performing structured training paths: from the “simple” case to the “complex” case

The in vitro mimicking of bone microenvironment for the study of pathologies is a challenging field that requires the design of scaffolds with suitable morphological, structural and cytocompatible properties. During last years, 3D in vitro tumour models have been developed to reproduce mechanical, biochemical and structural bone microenvironment elements, allowing cells to behave as in vivo. In this work, gas foamed polyether urethane foams (PUF) and 3D printed thermoplastic polyether urethane (3DP-PU) designed with different patterns are proposed as scaffolds for in vitro model of bone tissue. Surface coatings for a biomimetic behaviour of the 3D scaffold models were also investigated. Morphological, chemico-physical, mechanical properties, and biological in vitro behaviour were investigated. PUFs for metastases investigation. The suitability of PUF as 3D in vitro model to study the interactions between bone tumour initiating cells and the bone microenvironment was investigated. PUF open porosity (>70%) appeared suitable to mimic trabecular bone structure. Human adipose derived stem cells (ADSC) were cultured and differentiated into osteoblast lineage on the PU foam, as confirmed by Alizarin Red staining and RT-PCR, thus offering a bone biomimetic microenvironment to the further co-culture with bone derived tumour-initiating cells (MCFS). Tumour aggregates were observed after three weeks of co-culture by e-cadherin staining and SEM; modification in CaP distribution was identified by SEM-EDX and associated to the presence of tumour cells. 3DP-PU as tumour bone model. 3D printed scaffolds have pores with a precise and regular geometry (0°-90°, 0°-45°-90°-135°, 0°-60°-120°). PU scaffold porosity evidenced values from 55 to 67%, values that belong to the porosity range of the trabecular bone tissue (30-90%). The compressive modulus varied between 2 and 4 MPa, depending on the printed pattern. Biomimetic nanostructured coating was performed on 0-90° 3DP-PU by Ionized Jet Deposition. Coatings had a submicrometric thickness, variable tuning deposition time, nanostructured surface morphology and biomimetic composition. Coating on 3DP-PU promoted cells colonization of the whole porous scaffolds, compared to the controls, where cells concentrated mostly on the outer layers. In conclusion, based on the obtained results, scaffolds with different geometries have been successfully produced. Morphological and structural properties of the scaffolds here presented are suitable for mimicking the bone tissue, in order to produce a 3D in vitro model useful for bone pathologies research

Background. Dislocation is a common complication after proximal and total femur prosthesis reconstruction for primary bone sarcoma patients. Expandable prosthesis in children puts an additional challenge due to the lengthening process. Hip stability is impaired due to multiple factors: Resection of the hip stabilizers as part of the sarcoma resection: forces acts on the hip during the lengthening; and mismatch of native growing acetabulum to the metal femoral head. Surgical solutions described in literature are various with reported low rates of success. Objective. Assess a novel 3D surgical planning technology by use of 3D models (computerized and physical), 3D planning, and Patient Specific Instruments (PSI) in supporting correction of young children suffering from hip instability after expandable prosthesis reconstruction following proximal femur resection. This innovative technology creates a new dimension of visualization and customization, and could improve understanding of this complex problem and facilitate the surgical decision making and procedure. Method. Two children, both patients with Ewing Sarcoma of the left proximal femur stage-IIB, ages 3/5 years at diagnosis, were treated with conventional chemotherapy followed by proximal femur resection. Both were reconstructed with expandable prosthesis (one at resection and other 4 years after resection). Hip migration developed gradually during lengthening process in the 24m follow up period. 3D software (Mimics, Materialise, Belgium) were used to make computerized 3D models of patients' pelvises. These were used to 3D print 1:1 physical models. Custom 3D planning software (MSk Lab, Imperial College London) allowed surgeons visualizing the anatomical status and assess of problem severity. Thereafter, osteotomies planes and the desired position of acetabular roof after reduction of hip joint were planned by the surgeons. These plans were used to generate 3D printed PSIs to guide the osteotomies during shelf and triple osteotomy surgeries. Accuracy of planning and PSIs were verified with fluoroscopy and post-op X-rays, by comparing cutting planes and post-op position of the acetabulum. Results. Surgeons reported excellent experience with the 3D models (computerized and physical). It helped them in the decision process with an improved understanding of the relationship between prosthesis head and acetabulum, a clear view of the osteophytes and bone formation surrounding the pseudoacetabulum, and osteophytes inside the native acetabulum. These osteophytes were not immediately visible on 2D CT imaging slices. Surgeons reported a good fit and PSIs' simplicity of use. The hip stability was satisfactory during surgery and in the immediate post-op period. X-ray showed a good and centered position of the hip and good levels of the osteotomies. Conclusions. 3D surgical planning and 3D printing was found to be very effective in assisting surgeons facing complex problems. In these particular cases neither CT nor MRI were able to visualize all bony formation and entrapment of prosthesis in the pseudoacetabulum. 3D visualisation can be very helpful for surgical treatment decisions, and by planning and executing surgery with the guidance of PSIs, surgeons can improve their surgical results. We believe that 3D technology and its advantages, can improve success rates of hip stability in this unique cohort of patients

Meniscal injuries affect over 1.5 million people across Europe and the USA annually. Injury greatly reduces knee joint mobility and quality of life and frequently leads to the development of osteoarthritis. Tissue engineered strategies have emerged in response to a lack of viable treatments for meniscal pathologies. However, to date, constructs mimicking the structural and functional organisation of native tissue, whilst promoting deposition of new extracellular matrix, remains a bottleneck in meniscal repair. 3D bioprinting allows for deposition and patterning of biological materials with high spatial resolution. This project aims to develop a biomimetic 3D bioprinted meniscal substitute. Meniscal tissue was characterised to effectively inform the design of biomaterials for bioprinting constructs with appropriate structural and functional properties. Histology, gene expression and mass spectrometry were performed on native tissue to investigate tissue architecture, matrix components, cell populations and protein expression regionally across the meniscus. 3D laser scanning and magnetic resonance imaging were employed to acquire the external geometrical information prior to fabrication of a 3D printed meniscus. Bioink suitability was investigated through regional meniscal cell encapsulation in blended hydrogels, with the incorporation of growth factors and assessed for their suitability through rheology, scanning electron microscopy, histology and gene expression analysis. Meniscal tissue characterisation revealed regional variations in matrix compositions, cellular populations and protein expression. The process of imaging through to 3D printing highlighted the capability of producing a construct that accurately replicated meniscal geometries. Regional meniscal cell encapsulation into hydrogels revealed a recovery in cell phenotype, with the incorporation of growth factors into the bioink's stimulating cellular re-differentiation and improved zonal functionality. Meniscus biofabrication highlights the potential to print patient specific, customisable meniscal implants. Achieving zonally distinct variations in cell and matrix deposition highlights the ability to fabricate a highly complex tissue engineered construct. Acknowledgements: This work was undertaken as part of the UK Research and Innovation (UKRI)-funded CDT in Advanced Biomedical Materials

Among the advanced technology developed and tested for orthopaedic surgery, the Rizzoli (IOR) has a long experience on custom-made design and implant of devices for joint and bone replacements. This follows the recent advancements in additive manufacturing, which now allows to obtain products also in metal alloy by deposition of material layer-by-layer according to a digital model. The process starts from medical image, goes through anatomical modelling, prosthesis design, prototyping, and final production in 3D printers and in case post-production. These devices have demonstrated already to be accurate enough to address properly the specific needs and conditions of the patient and of his/her physician. These guarantee also minimum removal of the tissues, partial replacements, no size related issues, minimal invasiveness, limited instrumentation. The thorough preparation of the treatment results also in a considerable shortening of the surgical and of recovery time. The necessary additional efforts and costs of custom-made implants seem to be well balanced by these advantages and savings, which shall include the lower failures and revision surgery rates. This also allows thoughtful optimization of the component-to-bone interfaces, by advanced lattice structures, with topologies mimicking the trabecular bone, possibly to promote osteointegration and to prevent infection. IOR's experience comprises all sub-disciplines and anatomical areas, here mentioned in historical order. Originally, several systems of Patient-Specific instrumentation have been exploited in total knee and total ankle replacements. A few massive osteoarticular reconstructions in the shank and foot for severe bone fractures were performed, starting from mirroring the contralateral area. Something very similar was performed also for pelvic surgery in the Oncology department, where massive skeletal reconstructions for bone tumours are necessary. To this aim, in addition to the standard anatomical modelling, prosthesis design, technical/technological refinements, and manufacturing, surgical guides for the correct execution of the osteotomies are also designed and 3D printed. Another original experience is about en-block replacement of vertebral bodies for severe bone loss, in particular for tumours. In this project, technological and biological aspects have also been addressed, to enhance osteointegration and to diminish the risk of infection. In our series there is also a case of successful custom reconstruction of the anterior chest wall. Initial experiences are in progress also for shoulder and elbow surgery, in particular for pre-op planning and surgical guide design in complex re-alignment osteotomies for severe bone deformities. Also in complex flat-foot deformities, in preparation of surgical corrections, 3D digital reconstruction and 3D printing in cheap ABS filaments have been valuable, for indication, planning of surgery and patient communication; with special materials mimicking bone strength, these 3D physical models are precious also for training and preparation of the surgery. In Paediatric surgery severe multi planar & multifocal deformities in children are addressed with personalized pre-op planning and custom cutting-guides for the necessary osteotomies, most of which require custom allografts. A number of complex hip revision surgeries have been performed, where 3D reconstruction for possible final solutions with exact implants on the remaining bone were developed. Elective surgery has been addressed as well, in particular the customization of an original total ankle replacement designed at IOR. Also a novel system with a high-tibial-osteotomy, including a custom cutting jig and the fixation plate was tested. An initial experience for the design and test of custom ankle & foot orthotics is also in progress, starting with 3D surface scanning of the shank and foot including the plantar aspect. Clearly, for achieving these results, multi-disciplinary teams have been formed, including physicians, radiologists, bioengineers and technologists, working together for the same goal

Aims. Although CT is considered the benchmark to measure femoral version, 3D biplanar radiography (hipEOS) has recently emerged as a possible alternative with reduced exposure to ionizing radiation and shorter examination time. The aim of our study was to evaluate femoral stem version in postoperative total hip arthroplasty (THA) patients and compare the accuracy of hipEOS to CT. We hypothesize that there will be no significant difference in calculated femoral stem version measurements between the two imaging methods. Methods. In this study, 45 patients who underwent THA between February 2016 and February 2020 and had both a postoperative CT and EOS scan were included for evaluation. A fellowship-trained musculoskeletal radiologist and radiological technician measured femoral version for CT and 3D EOS, respectively. Comparison of values for each imaging modality were assessed for statistical significance. Results. Comparison of the mean postoperative femoral stem version measurements between CT and 3D hipEOS showed no significant difference (p = 0.862). In addition, the two version measurements were strongly correlated (r = 0.95; p < 0.001), and the mean paired difference in postoperative femoral version for CT scan and 3D biplanar radiography was -0.09° (95% confidence interval -1.09 to 0.91). Only three stem measurements (6.7%) were considered outliers with a > 5° difference. Conclusion. Our study supports the use of low-dose biplanar radiography for the postoperative assessment of femoral stem version after THA, demonstrating high correlation with CT. We found no significant difference for postoperative femoral version when comparing CT to 3D EOS. We believe 3D EOS is a reliable option to measure postoperative femoral version given its advantages of lower radiation dosage and shorter examination time. Cite this article: Bone Joint J 2022;104-B(11):1196–1201

The computational modelling and 3D technology are finding more and more applications in the medical field. Orthopedic surgery is one of the specialties that can benefit the most from this solution. Three case reports drawn from the experience of the authors’ Orthopedic Clinic are illustraded to highlight the benefits of applying this technology. Drawing on the extensive experience gained within the authors’ Operating Unit, three cases regarding different body segments have been selected to prove the importance of 3D technology in preoperative planning and during the surgery. A sternal transplant by allograft from a cryopreserved cadaver, the realization of a custom made implant of the glenoid component in a two-stage revision of a reverse shoulder arthroplasty, and a case of revision on a hip prosthesis with acetabular bone loss (Paprosky 3B) treated with custom system. In all cases the surgery was planned using 3D processing software and models of the affected bone segments, printed by 3D printer, and based on CT scans of the patients. The surgical implant was managed with dedicated instruments. The use of 3D technology can improve the results of orthopedic surgery in many ways: by optimizing the outcomes of the operation as it allows a preliminary study of the bone loss and an evalutation of feasibility of the surgery, it improves the precision of the positioning of the implant, especially in the context of severe deformity and bone loss, and it reduces the operating time; by improving surgeon training; by increasing patient involvement in decision making and informed consent. 3D technology, by offering targeted and customized solutions, is a valid tool to obtain the tailored care that every patient needs and deserves, also providing the surgeon with an important help in cases of great complexity

Introduction. In the evaluation of patients with pre-arthritic hip disorders, making the correct diagnosis and identifying the underlying bone pathology is of upmost importance to achieve optimal patient outcomes. 3-dimensional imaging adds information for proper preoperative planning. CT scans have become the gold standard for this, but with the associated risk of radiation exposure to this generally younger patient cohort. Purpose. To determine if 3D-MR reconstructions of the hip can be used to accurately demonstrate femoral and acetabular morphology in the setting of femoroacetabular impingement (FAI) and development dysplasia of the hip (DDH) that is comparable to CT imaging. Materials and Methods. We performed a retrospective review of 14 consecutive patients with a diagnosis of FAI or DDH that underwent both CT and MRI scans of the same hip with 3D reconstructions. 2 fellowship trained musculoskeletal radiologists reviewed all scans, and a fellowship trained hip preservation surgeon separately reviewed scans for relevant surgical parameters. All were blinded to the patients' clinical history. The 3D reconstructions were evaluated by radiologists for the presence of a CAM lesion and acetabular retroversion, while the hip preservation surgeon also evaluated CAM extent using a clock face convention of a right hip, location of femoral head blood supply, and morphological anterior inferior iliac spine (AIIS) variant. The findings on the 3D CT reconstructions were considered the reference standard. Results. Of 14 patients, there were 9 females and 5 males with a mean age 32 (range 15–42). There was no difference in the ability of MRI to detect the presence of a CAM lesion (100% agreement between 3D-MR and 3D-CT, p=1), AIIS morphology (p=1, mode=type 1 variant), or acetabular retroversion (85.7%, p=0.5). 3D-MR had a sensitivity and specificity of 100 in detecting a CAM lesion relative to 3D-CT. Four CT studies were inadequate to adequately evaluate for presence of a CAM. Five CT studies were inadequate to evaluate for location of the femoral head vessels, while MRI was able to determine location in those patients. In the 10 remaining patients for presence of CAM, and nine patients for femoral head vessel location, there was no statistically significant difference between 3D-MR and 3D-CT in determining the location of CAM lesion on a clock face (p=0.8, mean MRI = 12:54, mean CT: 12:51, SD = 66 mins MR, 81 mins CT) or in determining vessel location (p=0.4, MR mean 11:23, CT mean 11:36, SD 33 mins for both). Conclusion. 3D MRI reconstructions are as accurate as 3D CT reconstructions in evaluating osseous morphology of the hip, and may be superior to CT in determining other certain clinically relevant hip parameters. 3D-MR was equally useful in determining the presence and extent of a CAM lesion, acetabular retroversion, and AIIS morphologic variant, and more useful than 3D CT in determining location of the femoral head vessels. In evaluating FAI or hip dysplasia, a 3D-MR study is sufficient to evaluate both soft tissue and osseous anatomy, sparing the need for a 3D CT scan and its associated radiation exposure and cost

Aims. The objective of this study is to assess the use of ultrasound (US) as a radiation-free imaging modality to reconstruct 3D anatomy of the knee for use in preoperative templating in knee arthroplasty. Methods. Using an US system, which is fitted with an electromagnetic (EM) tracker that is integrated into the US probe, allows 3D tracking of the probe, femur, and tibia. The raw US radiofrequency (RF) signals are acquired and, using real-time signal processing, bone boundaries are extracted. Bone boundaries and the tracking information are fused in a 3D point cloud for the femur and tibia. Using a statistical shaping model, the patient-specific surface is reconstructed by optimizing bone geometry to match the point clouds. An accuracy analysis was conducted for 17 cadavers by comparing the 3D US models with those created using CT. US scans from 15 users were compared in order to examine the effect of operator variability on the output. Results. The results revealed that the US bone models were accurate compared with the CT models (root mean squared error (RM)S: femur, 1.07 mm (SD 0.15); tibia, 1.02 mm (SD 0.13). Additionally, femoral landmarking proved to be accurate (transepicondylar axis: 1.07° (SD 0.65°); posterior condylar axis: 0.73° (SD 0.41°); distal condylar axis: 0.96° (SD 0.89°); medial anteroposterior (AP): 1.22 mm (SD 0.69); lateral AP: 1.21 mm (SD 1.02)). Tibial landmarking errors were slightly higher (posterior slope axis: 1.92° (SD 1.31°); and tubercle axis: 1.91° (SD 1.24°)). For implant sizing, 90% of the femora and 60% of the tibiae were sized correctly, while the remainder were only one size different from the required implant size. No difference was observed between moderate and skilled users. Conclusion. The 3D US bone models were proven to be closely matched compared with CT and suitable for preoperative planning. The 3D US is radiation-free and offers numerous clinical opportunities for bone visualization rapidly during clinic visits, to enable preoperative planning with implant sizing. There is potential to extend its application to 3D dynamic ligament balancing, and intraoperative registration for use with robots and navigation systems. Cite this article: Bone Joint J 2021;103-B(6 Supple A):81–86

3D printing techniques have attracted a lot of curiosity in various surgical specialties and the applications of the 3D technology have been explored in many ways including fracture models for education, customized jigs, custom implants, prosthetics etc. Often the 3D printing technology remains underutilized in potential areas due to costs and technological expertise being the perceived barriers. We have applied 3D printing technology for acetabular fracture surgeries with in-house, surgeon made models of mirrored contralateral unaffected acetabulum based on the patients’ trauma CT Scans in 9 patients. The CT Scans are processed to the print with all free-ware modeling software and relatively inexpensive printer by the surgeon and the resulting model is used as a ‘reduced fracture template’ for pre-contouring the standard pelvic reconstruction plates. This allows use of the standard surgical implants, saves time on intra-operative plate contouring, and also aids in reduction to an extent. We share through this presentation the workflow of the freeware softwares to use in order to use this surgical planning and implant preparation that may remove the perceived barriers of cost and technology from surgeons that wish to explore using 3D printing technology for acetabular fracture management and may extend applications to other regions

Aims. The use of 3D printing has become increasingly popular and has been widely used in orthopaedic surgery. There has been a trend towards an increasing number of publications in this field, but existing literature incorporates limited high-quality studies, and there is a lack of reports on outcomes. The aim of this study was to perform a scoping review with Level I evidence on the application and effectiveness of 3D printing. Methods. A literature search was performed in PubMed, Embase, and Web of Science databases. The keywords used for the search criteria were ((3d print*) OR (rapid prototyp*) OR (additive manufactur*)) AND (orthopaedic). The inclusion criteria were: 1) use of 3D printing in orthopaedics, 2) randomized controlled trials, and 3) studies with participants/patients. Risk of bias was assessed with Cochrane Collaboration Tool and PEDro Score. Pooled analysis was performed. Results. Overall, 21 studies were included in our study with a pooled total of 932 participants. Pooled analysis showed that operating time (p < 0.001), blood loss (p < 0.001), fluoroscopy times (p < 0.001), bone union time (p < 0.001), pain (p = 0.040), accuracy (p < 0.001), and functional scores (p < 0.001) were significantly improved with 3D printing compared to the control group. There were no significant differences in complications. Conclusion. 3D printing is a rapidly developing field in orthopaedics. Our findings show that 3D printing is advantageous in terms of operating time, blood loss, fluoroscopy times, bone union time, pain, accuracy, and function. The use of 3D printing did not increase the risk of complications. Cite this article: Bone Joint Res 2021;10(12):807–819

Anatomically specific fixation devices have become mainstream, yet there are anatomical regions and clinical conditions where no pre-contoured plates are available, such as for glenohumeral arthrodesis. In a case series of 4 glenohumeral arthrodesis patients, a consultant orthopaedic surgeon at GCUH implemented 3D printing technology to create reconstructions of each patient's shoulder girdle to pre-contour arthrodesis plates. Our aim was to quantify the cost-benefit & intra-operative time savings of this technique in glenohumeral arthrodesis. We hypothesized that the use of 3D printing for creating patient specific implants through pre-operative contouring of plates will lead to intra-operative time and cost savings by minimising time spent bending plates during surgery. This study analysed 4 patients who underwent shoulder arthrodesis by a single consultant orthopaedic surgeon at GCUH between 2017-2021. A CT-based life-size model of each patient's shoulder girdle was 3D printed using freely available computer software programs: 3D Slicer, Blender, Mesh Mixer & Cura. Once the patient's 3D model was created, plate benders were used to contour the plate pre-op, which was then sterilised prior to surgery. Arthrodesis was performed according to AO principles of fixation. The time spent pre-bending the plate using the 3D model was calculated to analyse the intra-op time and cost-saving benefits. For the 4 cases, the plate pre-bending times were 45, 40, 45 & 20 minutes (average 38.8 mins). The intra-op correction time to make small adjustments to the plate was 2 min/ case. 3 plates needed minor (3 degree) adjustment to fine-tune scapula spine contouring. 1 plate needed a 5 degree correction to fine-tune hand position. On average, the pre-bending of the plate saved approximately 38.8 mins intra-op/ case. These shorter anaesthetic and operating times equate to approximately $2586 saving/ case, given an estimate of $4000/hour of theatre costs. We conclude that pre-bending plates around 3D-printed life-size models of an individual's shoulder girdle prior to surgery results in approximately 38.8 mins time saving intra-op when used in shoulder arthrodesis. This is a viable and effective technique that will ultimately result in significant operative time and financial savings

As arthroplasty demand grows worldwide, the need for a novel cost-effective treatment option for articular cartilage (AC) defects tailored to individual patients has never been greater. 3D bioprinting can deposit patient cells and other biomaterials in user-defined patterns to build tissue constructs from the “bottom-up,” potentially offering a new treatment for AC defects. The aim of this research was to create bioinks that can be injected or 3D bioprinted to aid osteochondral defect repair using human cells. Novel composite bioinks were created by mixing different ratios of methacrylated alginate (AlgMA) with methacrylated gelatin (GelMA). Chondrocytes or mesenchymal stem cells (MSCs) were then encapsulated in the bioinks and 3D bioprinted using a custom-built extrusion bioprinter. UV and double-ionic (BaCl2 and CaCl2) crosslinking was deployed following bioprinting to strengthen bioink stability in culture. Chondrocyte and MSC spheroids were also produced via 3D culture and then bioprinted to accelerate cell growth and development of ECM in bioprinted constructs. Excellent viability of chondrocytes and MSCs was seen following bioprinting (>95%) and maintained in culture over 28 days, with accelerated cell growth seen with inclusion of MSC or chondrocyte spheroids in bioinks (p<0.05). Bioprinted 10mm diameter constructs maintained shape in culture over 28 days, whilst construct degradation rates and mechanical properties were improved with addition of AlgMA (p<0.05). Composite bioinks were also injected into in vitro osteochondral defects (OCDs) and crosslinked in situ, with maintained cell viability and repair of osteochondral defects seen over a 14-day period. In conclusion we developed novel composite AlgMA/GelMA bioinks that can be triple-crosslinked, facilitating dense chondrocyte and MSC growth in constructs following 3D bioprinting. The bioink can be injected or 3D bioprinted to successfully repair in vitro OCDs, offering hope for a new approach to treating AC defects