Introduction

As population grows older, and patients receive primary joint replacements at younger age, more and more patients receive a total hip prosthesis nowadays. Ten-year failure rates of revision hip replacements are estimated at 25.6%. The acetabular component is involved in over 58% of those failures. From the second revision on, the pelvic bone stock is significantly reduced and any standard device proves inadequate in the long term [Villanueva et al. 2008]. To deal with these challenges, a custom approach could prove valuable [Deboer et al. 2007].

Although the introduction of ultraporous metals in the forms of acetabular components and augments has substantially improved the orthopaedic surgeon's ability to reconstruct severely compromised acetabuli, there remain some revision THAs that are beyond the scope of cups, augments, and cages. In situations involving catastrophic bone loss, allograft-prosthetic composites or custom acetabular components may be considered. Custom components offer the potential advantages of immediate, rigid fixation with a superior fit individualised to each patient. These custom triflange components require a preoperative CT scan with three-dimensional (3-D) reconstruction using rapid prototyping technology, which has evolved substantially during the past decade. The surgeon can fine-tune exact component positioning, determine location and length of screws, modify the fixation surface with, for example, the addition of hydroxyapatite, and dictate which screws will be locked to enhance fixation. The general indications for using custom triflange components include: (1) failed prior salvage reconstruction with cage or porous metal construct augments, (2) large contained defects with possible discontinuity, (3) known pelvic discontinuity, and (4) complex multiply surgically treated hips with insufficient bone stock to reconstruct using other means. We previously reported on our center's experience with 23 patients (24 hips) treated with custom triflange components with minimum 2-year follow-up. This method of reconstruction was used in a cohort of patients with Paprosky Type 3B acetabular defects, which represented 3% (30 of 955) of the acetabular revisions we performed during the study period of 2003 to 2012. At a mean follow-up of 4.8 years (range, 2.3 – 9 years) there were four subsequent surgical interventions: two failures secondary to sepsis, and one stem revision and one open reduction internal fixation for periprosthetic femoral fracture. There were two minor complications managed nonoperatively, but all of the components were noted to be well-fixed with no obvious migration or loosening observed on the most recent radiographs. Harris hip scores improved from a mean of 42 (SD ±16) before surgery to 65 (SD ±18) at latest follow-up (p < 0.001). More recently, we participated in a multi-center study of 95 patients treated with reconstruction using custom triflange components who had a mean follow-up of 3.5 years. Pelvic defects included Paprosky Type 2C, 3A, 3B and pelvic discontinuity. Concomitant femoral revision was performed in 21 hips. Implants used a mean of 12 screws with 3 locking screws. Twenty of 95 patients (21%) experienced at least one complication, including 6% dislocation, 6% infection, and 2% femoral-related issues. Implants were ultimately removed in 11% of hips. One hip was revised for possible component loosening. Survivorship with aseptic loosening as the endpoint was 99%. Custom acetabular triflange components represent yet another tool in the reconstructive surgeon's armamentarium. These devices can be helpful in situations of catastrophic bone loss, achieving reliable fixation. Clinical results are inferior to both primary THA and more routine revision THA. Patients and surgeons should be aware of the increased complications associated with these complex hip revisions

Additive manufacturing has enabled a radical change in how surgeons reconstruct massive acetabular defects in revision hip surgery. We report on the early clinical and radiological results from our methods for surgical planning, design, and implantation of 3D printed trabecular titanium implants in a cohort of patients with large unclassifiable pelvic defects. We set up a prospective investigation involving 7 consecutive patients. Inclusion criteria was the following: 1) A history of previous total hip replacement; and 2) Current imaging showing at least a Paprosky 3B defect. Planned acetabular inclination and version was 40° and 20° respectively. Post operatively all patients had a CT scan which was analysed with software to determine component position and compared to planned. Outpatient review was done at 2 weeks (For wound), 6 weeks (for weight bearing and fixation) and 52 weeks (for fixation and infection) post-operative. The median age at surgery was: 65 years (40–78). The median bone defect volume was 140cm. 3. Median surgery length was 5.2 hours (3–6.25). Median blood loss was 1300mL (450– 2000). Radiologically, components were stable and no screw breakages were identified. Achieved inclination was 41.0° (29.0–55.6) and achieved version was 15.8° (3.8–43.6). Median Oxford Hip score improved from 9 (2–44) to 25 (18–32). We have demonstrated a new series of pre, intra and post-operative methods for reconstruction of unclassifiable acetabular bony defects. Initial clinical and radiological results are excellent considering the severity of the bony defects. We recommend the use of our or similar methods when trying to reconstruct these defects

Although the introduction of ultraporous metals in the forms of acetabular components and augments has substantially improved the orthopaedic surgeon's ability to reconstruct severely compromised acetabuli, there remain some revision THAs that are beyond the scope of cups, augments, and cages. In situations involving catastrophic bone loss, allograft-prosthetic composites or custom acetabular components may be considered. Custom components offer the potential advantages of immediate, rigid fixation with a superior fit individualised to each patient. These custom triflange components require a pre-operative CT scan with 3-D reconstruction using rapid prototyping technology. The surgeon can fine-tune exact component positioning, determine location and length of screws, modify the fixation surface with, for example, the addition of hydroxyapatite, and dictate which screws will be locked to enhance fixation. The general indications for using custom triflange components include: (1) failed prior salvage reconstruction with cage or porous metal construct augments, (2) large contained defects with possible discontinuity, (3) known pelvic discontinuity, and (4) complex multiply surgically treated hips with insufficient bone stock to reconstruct using other means. The general indications for using custom triflange components include: (1) failed prior salvage reconstruction with cage or porous metal construct augments, (2) large contained defects with possible discontinuity, (3) known pelvic discontinuity, and (4) complex multiply surgically treated hips with insufficient bone stock to reconstruct using other means. We previously reported on our center's experience with 23 patients (24 hips) treated with custom triflange components with minimum 2-year follow-up. This method of reconstruction was used in a cohort of patients with Paprosky Type 3B acetabular defects, which represented 3% (30 of 955) of the acetabular revisions we performed during the study period of 2003 to 2012. At a mean follow-up of 4.8 years (range, 2.3–9 years) there were 4 subsequent surgical interventions: 2 failures secondary to sepsis, and 1 stem revision and 1 open reduction internal fixation for periprosthetic femoral fracture. There were two minor complications managed non-operatively, but all of the components were noted to be well-fixed with no obvious migration or loosening observed on the most recent radiographs. Harris Hip Scores improved from a mean of 42 (SD ±16) before surgery to 65 (SD ±18) at latest follow-up (p<0.001). More recently, we participated in a multi-center study of 95 patients treated with reconstruction using custom triflange components w a mean follow-up of 3.5 years. Pelvic defects included Paprosky Type 2C, 3A, 3B and pelvic discontinuity. Concomitant femoral revision was performed in 21 hips. Implants used a mean of 12 screws with 3 locking screws. Twenty of 95 patients (21%) experienced at least one complication, including 6% dislocation, 6% infection, and 2% femoral-related issues. Implants were ultimately removed in 11% of hips. One hip was revised for possible component loosening. Survivorship with aseptic loosening as the endpoint was 99%. Custom acetabular triflange components represent yet another tool in the reconstructive surgeon's armamentarium. These devices can be helpful in situations of catastrophic bone loss, achieving reliable fixation. Clinical results are inferior to both primary THA and more routine revision THA. Patients and surgeons should be aware of the increased complications associated with these complex hip revisions

Although the introduction of ultraporous metals in the forms of acetabular components and augments has substantially improved the orthopaedic surgeon's ability to reconstruct severely compromised acetabuli, there remain some revision THAs that are beyond the scope of cups, augments, and cages. In situations involving catastrophic bone loss, allograft-prosthetic composites or custom acetabular components may be considered. Custom components offer the potential advantages of immediate, rigid fixation with a superior fit individualised to each patient. These custom triflange components require a pre-operative CT scan with three-dimensional (3-D) reconstruction using rapid prototyping technology, which has evolved substantially during the past decade. The surgeon can fine-tune exact component positioning, determine location and length of screws, modify the fixation surface with, for example, the addition of hydroxyapatite, and dictate which screws will be locked to enhance fixation. The general indications for using custom triflange components include: (1) failed prior salvage reconstruction with cage or porous metal construct augments, (2) large contained defects with possible discontinuity, (3) known pelvic discontinuity, and (4) complex multiply surgically treated hips with insufficient bone stock to reconstruct using other means. The general indications for using custom triflange components include: (1) failed prior salvage reconstruction with cage or porous metal construct augments, (2) large contained defects with possible discontinuity, (3) known pelvic discontinuity, and (4) complex multiply surgically treated hips with insufficient bone stock to reconstruct using other means. We previously reported on our center's experience with 23 patients (24 hips) treated with custom triflange components with minimum 2-year follow-up. This method of reconstruction was used in a cohort of patients with Paprosky Type 3B acetabular defects, which represented 3% (30 of 955) of the acetabular revisions we performed during the study period of 2003 to 2012. At a mean follow-up of 4.8 years (range, 2.3–9 years) there were 4 subsequent surgical interventions: 2 failures secondary to sepsis, and 1 stem revision and 1 open reduction internal fixation for periprosthetic femoral fracture. There were 2 minor complications managed nonoperatively, but all of the components were noted to be well-fixed with no obvious migration or loosening observed on the most recent radiographs. Harris hip scores improved from a mean of 42 (SD ± 16) before surgery to 65 (SD ± 18) at latest follow-up (p<0.001). More recently, we participated in a multi-center study of 95 patients treated with reconstruction using custom triflange components who had a mean follow-up of 3.5 years. Pelvic defects included Paprosky Type 2C, 3A, 3B and pelvic discontinuity. Concomitant femoral revision was performed in 21 hips. Implants used a mean of 12 screws with 3 locking screws. Twenty of 95 patients (21%) experienced at least one complication, including 6% dislocation, 6% infection, and 2% femoral-related issues. Implants were ultimately removed in 11% of hips. One hip was revised for possible component loosening. Survivorship with aseptic loosening as the endpoint was 99%,. Custom acetabular triflange components represent yet another tool in the reconstructive surgeon's armamentarium. These devices can be helpful in situations of catastrophic bone loss, achieving reliable fixation. Clinical results are inferior to both primary THA and more routine revision THA. Patients and surgeons should be aware of the increased complications associated with these complex hip revisions